Nonwoven Webs With Hydrophobic And Hydrophilic Layers

ABSTRACT

A nonwoven web for use in an absorbent article is described. The nonwoven web has first and second nonwoven layers. The first nonwoven layer has a first plurality of fibers, an additive disposed, at least in part, on a portion of the first plurality of fibers, a first side and an opposing second side, wherein second side has a plurality of discontinuities. The second nonwoven layer has a second plurality of fibers, a first surface and an opposing second surface, and a plurality of tufts extending through at least a portion of the discontinuities in the first nonwoven layer, wherein the second nonwoven layer is attached to the first nonwoven layer such that at least a portion of the second plurality of fibers are in liquid communication with the first nonwoven layer, wherein the first nonwoven layer is hydrophobic and the second nonwoven layer is hydrophilic.

FIELD OF THE INVENTION

The disclosure herein relates generally to a nonwoven web and an articleincorporating the nonwoven web.

BACKGROUND OF THE INVENTION

Topsheets of disposable absorbent articles perform a valuable function.Topsheets are typically the interface between the disposable absorbentarticle and the user. As such, topsheets should be tactilely appealingto the user. Additionally, particularly in the context of hygienearticles, topsheets should blur/mask staining caused by menses and/orurine. If the topsheet does not successfully blur/mask the stainingcaused by menses/urine, the user may be left with the impression thatthe disposable absorbent article did not perform well.

There are a variety of top sheets known in the art. For example, in someconventional feminine hygiene articles, topsheets may comprise a film.Films are typically desirable because they provide good blurring/maskingbenefits regarding menses/urine staining. However, films are generallynot considered to be soft without additional processing. Additionally,even with the additional processing, some users describe the filmtopsheet as having a “plastic feel”. And, films can sometimes leaveresidual liquid, e.g. menses and/or urine, in contact with the skin ofthe wearer which can create an unpleasant feel as well as create an“unclean” perception in the mind of the user.

Other conventional feminine hygiene articles comprise nonwoventopsheets. Nonwoven topsheets can provide a soft feel to the user;however, nonwoven topsheets typically do not have good blurring/maskingcapability with regard to menses/urine stains.

Based on the foregoing, there is a need for a topsheet which can providea soft feel to the user while also providing good masking ofmenses/urine stains.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter of the present invention, itis believed that the invention can be more readily understood from thefollowing description taken in connection with the accompanyingdrawings, in which:

FIG. 1A is an exploded view of a nonwoven web of the present invention;

FIG. 1B is an exploded view of another embodiment of a nonwoven web ofthe present invention;

FIG. 2A is a side view of another embodiment of a nonwoven web of thepresent invention;

FIG. 2B is a side view of another embodiment of a nonwoven web of thepresent invention;

FIG. 2C is a side view of another embodiment of a nonwoven web of thepresent invention;

FIG. 3 is a close up view of a tuft and cap of the embodiments of FIGS.2A-2C;

FIG. 4 is a cross sectional view showing the tuft and cap of FIG. 3 andtaken along line 4-4 of FIG. 3;

FIG. 5 is a plan view of the tuft and cap shown in FIG. 3;

FIG. 6 is a plan view of the tuft and cap shown in FIG. 3;

FIG. 7 is a side view of another embodiment of a nonwoven web of thepresent invention;

FIG. 8 is a side view of another embodiment of a nonwoven web of thepresent invention;

FIG. 9 is a side view of another embodiment of a nonwoven web of thepresent invention;

FIG. 10 is a perspective view showing an apparatus for producing some ofthe nonwoven webs of the present invention;

FIG. 11 is a scanning electron micrograph (“SEM”) photo showing anonwoven fiber with additive that has bloomed on the surface of thefiber;

FIG. 12 is an SEM photo showing another nonwoven fiber with additivethat has bloomed on the surface of the fiber;

FIG. 13 is an SEM photo showing another nonwoven fiber with additivethat has bloomed on the surface of the fiber;

FIG. 14 is an SEM photo showing another nonwoven fiber with additivethat has bloomed on the surface of the fiber;

FIG. 15 is an SEM photo showing another nonwoven fiber with additivethat has bloomed on the surface of the fiber;

FIG. 16 is an SEM photo showing other nonwoven fibers with additive thathas been applied to the fibers;

FIG. 17 is an SEM photo showing nonwoven fibers with additive that hasformed a film on the surface of the fibers;

FIG. 18 is an SEM photo showing nonwoven fibers with additive that hasformed a film and fibrils on the surface of the fibers;

FIGS. 19A-19C are SEM photos showing crimped fiber nonwovens comprisingmelt additives; and

FIGS. 20A-20C are SEM photos showing a sprayed on topical hydrophobictreatment at varying basis weights.

DETAILED DESCRIPTION OF THE INVENTION

The term “fibrils” refers to projections, elongate projections, bumpsthat extend outwardly from a surface or generally radially outwardlyfrom an outer surface of a fiber. In some instances, the projections,elongate projections, or bumps may extend radially outwardly relative toa longitudinal axis of the fiber. Radially outwardly means in the rangeof 1 to 89 degrees relative to the longitudinal axis. In still otherinstances, the projections, elongate projections, or bumps may extendradially outwardly from a surface of a fiber at least in a longitudinalcentral third of the fiber. The projections, elongate projections, orbumps comprise, consist of, or consist essentially of (e.g., 51% to 100%or 51% to 99%), melt additives. The projections, elongate projections,or bumps grow from the fibers post-nonwoven substrate formation onlyafter a time period (e.g., 6-100 hours) under ambient conditions.Fibrils can be viewed using an SEM at, at least 1,000 timesmagnification.

As used herein, the term “nonwoven web” refers to a web having astructure of individual fibers or threads which are interlaid, but notin a repeating pattern as in a woven or knitted fabric, which do nottypically have randomly oriented fibers. The basis weight of nonwovenfabrics is usually expressed in grams per square meter (gsm). The basisweight of a nonwoven web is the combined basis weight of the constituentlayers and any other added components. Fiber diameters are usuallyexpressed in microns; fiber size can also be expressed in denier, whichis a unit of weight per length of fiber.

As used herein “philic” and “phobic” have meanings as well establishedin the art with respect to the contact angle of a referenced liquid onthe surface of a material. Thus, a material having a liquid contactangle of greater than about 75 degrees is considered phobic, and amaterial having a liquid contact angle of less than about 75 degrees isconsidered philic.

By “substantially randomly oriented” it is meant that, due to processingconditions of a nonwoven layer, there may be a higher amount of fibersoriented in the machine direction (MD) than the cross direction (CD), orvice-versa.

The present invention pertains to a nonwoven web that is suitable foruse in a disposable absorbent article. In some embodiments, the nonwovenweb of the present invention is suitable for use as a topsheet in adisposable absorbent article. The nonwoven webs of the present inventioncomprise multiple layers of nonwoven material which can be integral ordiscrete as discussed herein. In some embodiments, the nonwoven web maycomprise caps and tufts which provide a softness benefit and a maskingbenefit. Additionally, at least one of the nonwoven layers may comprisean additive which blooms at the surface of at least a portion of theconstituent fibers of the at least one nonwoven layer. The inventorshave found that the additive can provide masking benefits such thatmenses stains are less visible to a user of the disposable absorbentarticle. Additionally, the inventors have found that the additive canprovide the treated nonwoven layer with better draining capability suchthat less fluid sticks to the fibers and/or interstices betweenintersecting fibers. The additive and its application to the nonwovenare similarly discussed hereafter. The better draining capability canlead to an increased feeling of dryness for the consumer.

In addition to tufts and/or caps or independently therefrom, webs of thepresent invention may comprise ridges and/or grooves. Ridges and/orgrooves generally have a much greater length than do tufts and/or caps.For example, ridges and/or grooves may extend across a width of a web inthe cross machine direction. In other forms, ridges and/or grooves mayextend parallel with a machine direction to a larger extent than tufts.Still in other examples, ridges and/or grooves may have a length which sgreater than a tuft and/or cap. In some forms, a plurality ofdiscontinuous ridges and/or grooves may be provided. Methods of formingridges and/or grooves are discussed further in U.S. Pat. No. 7,954,213;U.S. Patent Application Publication Nos. US2012/0045620; US2012/0196091;US2012/0321839; US2013/0022784; and US2013/0017370; and PCT PatentApplication Publication Nos. WO2011/125893; and WO2012/137553.

Nonwoven Web

Nonwoven webs of the present invention have a machine direction (MD)(perpendicular to the plane of the sheet showing FIGS. 1A, 1B, 2A-2C,and 7-9), a cross machine direction (CD), and a Z direction, as iscommonly known in the art of web manufacture. As stated previously, thenonwoven webs of the present invention comprise a laminate structurewhere the nonwoven web comprises a plurality of nonwoven materiallayers. The material layers may be discrete or may be integral asdiscussed hereafter. Additionally, each of the nonwoven webs of thepresent invention comprises at least two nonwoven material layers whichare referred to herein as generally planar, two-dimensional webs. Also,each of the constituent nonwoven layers is a fibrous nonwoven web.

FIG. 1A shows an exploded view of a first embodiment of a nonwoven web100A of the present invention. The first nonwoven layer 110 has a firstsurface 115 and a second surface 120, each of which are generallyplanar. Similarly, the second nonwoven layer 150A has a first surface155 and a second surface 160 each of which are generally planar. Thefirst surface 115 and 155 of the first nonwoven layer 110 and the secondnonwoven layer 150A, respectively, can be body-facing surfaces and thesecond surfaces 120 and 160 of the first nonwoven layer 110 and thesecond nonwoven layer 150A, respectively, can be garment-facingsurfaces.

The first nonwoven layer 110 and second nonwoven layer 150A can be anonwoven web comprised of substantially randomly oriented fibers. Forexample, the first nonwoven layer 110 comprises a first plurality ofsubstantially randomly oriented fibers, and the second nonwoven layer150A comprises a second plurality of substantially randomly orientedfibers.

In one embodiment, the first nonwoven layer 110 may comprise a firstplurality of apertures 125 that extend through the first nonwoven layer110 from the first surface 115 to the second surface 120. In anotherembodiment, as shown in FIG. 1B, nonwoven web 100B may comprise thefirst nonwoven layer 110 comprising the first plurality of apertures 125and a second nonwoven layer 150B comprising a second plurality ofapertures 165. The second nonwoven layer 150B may otherwise beconstructed similar to the second nonwoven layer 150A.

In some embodiments, the second plurality of apertures 165 may besubstantially aligned with the first plurality of apertures 125. Theaperturing of the first nonwoven layer 110 and the second nonwoven layer150A or 150B may be by any suitable method; however, in order to providethe blurring/masking benefits described heretofore, the second nonwovenlayer 150A, 150B should be in liquid communication with the firstplurality of apertures. Liquid communication means that liquid insultsto the first nonwoven layer are transferred to the second nonwovenlayer. Generally, more interaction between the constituent fibers of thesecond nonwoven layer with the first nonwoven layer, can result inbetter liquid communication between the first nonwoven layer and thesecond nonwoven layer.

Preferable methods of aperturing nonwoven webs are described hereafter.The first nonwoven layer 110 and the second nonwoven layer 150A, 150B,may be joined about the periphery of each of the first plurality ofapertures 125. For example, for those embodiments where apertures arecreated by melting fibers of the first nonwoven layer 110 typically anaperture periphery is formed. Additionally during the melting, themelted fiber material can form bonds with surrounding fibers includingthe fibers of the second nonwoven layer 150A or 150B. Where theconstituent fibers of the first nonwoven layer 150A and the secondnonwoven layer 150B are melted together, liquid communication betweenthe first nonwoven layer 150A and the second nonwoven layer 150B can beenhanced. The same can occur with regard to the embodiment where boththe first nonwoven layer 110 and the second nonwoven layer 150B compriseapertures. In some embodiments, the first nonwoven layer 110 and thesecond nonwoven layer 150A, 150B are attached to one another about atleast a portion of the periphery of each of the first plurality ofapertures 125. In some embodiments, the first nonwoven layer 110 and thesecond nonwoven layer 150A, 150B are attached to one another about atleast a portion of the periphery of each of the second plurality ofapertures 165.

The resultant nonwoven webs 100A and 100B of FIGS. 1A and 1B can providea soft feel to a user of an absorbent article incorporating either ofthe nonwoven webs 100A or 100B as the topsheet of the absorbent article.An additional softness benefit and/or masking benefits can be gained bythe structures described with regard to FIGS. 2A-2C and 8-10.

With regard to FIG. 2A, nonwoven web 200A constructed in accordance withthe present invention is shown. The nonwoven web 200A may comprise afirst nonwoven layer 210A having a generally planar first surface 215and a generally planar second surface 220 opposed to the first surface215 and a second nonwoven layer 250A having a generally planar firstsurface 255 and a generally planar second surface 260. The firstnonwoven layer 210A comprises a first plurality of substantiallyrandomly oriented fibers, and the second nonwoven layer 250A comprises asecond plurality of substantially randomly oriented fibers. At least aportion of the second plurality of fibers in the second nonwoven layer250A is in liquid communication with the first nonwoven layer 210A.Similar to the first nonwoven layer 110 and second nonwoven layers 150Aand 150B (shown in FIGS. 1A and 1B), the respective surfaces of thefirst nonwoven layer 210A and second nonwoven layer 250A, can bearranged such that the first surfaces 215 and 255, respectively, arebody-facing surfaces, and the second surfaces 220 and 260, respectively,can be arranged as garment-facing surfaces.

As shown, in some embodiments, the second surface 220 of the firstnonwoven layer 210A may comprise a first plurality of discontinuities235. The first plurality of discontinuities 235 are formed whenlocalized areas of constituent fibers of the first nonwoven layer 210Aare urged in the Z-direction such that these constituent fibers aredisposed superjacent to the first surface 215 of the first nonwovenlayer 210A. The disposition of the constituent fibers, may, in someembodiments, form a cap 230. The first nonwoven layer 210A may comprisea plurality of caps 230 positioned above the first surface 215. Each ofthe plurality of caps 230 can partially overlie at least one of thefirst plurality of discontinuities 235. For example, a first cap may atleast partially overly a first discontinuity, and a second cap may atleast partially overly a second discontinuity and so on. Caps 230 arediscussed in additional detail hereafter.

Similarly, in some embodiments, the second surface 260 of the secondnonwoven layer 250A may comprise a second plurality of discontinuities275. The second plurality of discontinuities 275 can be formed asprovided above with regard to the first plurality of discontinuities 235in the first nonwoven layer 210A. Namely, localized areas of constituentfibers of the second nonwoven layer 250A are urged in the Z-directionsuch that these constituent fibers are disposed superjacent to the firstsurface 255 of the second nonwoven layer 250A. In some embodiments, thisZ-direction urging also forces these constituent fibers to extendthrough the first plurality of discontinuities 235 in the second surface220 of the first nonwoven layer 210A. The urging of the constituentfibers of the second nonwoven layer 250A forms tufts 270.

Tufts 270 extend through at least a portion of the first plurality ofdiscontinuities 235 in the first nonwoven layer 210A. For example, tufts270 may extend through at least one of the plurality of discontinuities235 in the second surface 220 of the first nonwoven layers 210A and210B. In other examples, tufts 270 may extend through each of theplurality of discontinuities 235. Embodiments are contemplated wheretufts 270 of the second nonwoven layers 250A and 250B extend throughmore than about 90 percent of the plurality of discontinuities 235 inthe second surface 220. In other embodiments, tufts 270 of the secondnonwoven layer 250A and 250B extend through more than about 80 percentof the plurality of discontinuities 235, more than about 70 percent ofthe plurality of discontinuities 235, more than about 60 percent of theplurality of discontinuities 235, more than about 50 percent of theplurality of discontinuities 235, more than about 40 percent of theplurality of discontinuities 235, more than about 30 percent of theplurality of discontinuities 235, more than about 20 percent of theplurality of discontinuities, and/or less than about 100 percent, orless than about any of the above mentioned values or any number withinthe range of the values above or any range within the values above.Tufts 270 are discussed in additional detail hereafter.

The abrupt change of orientation exhibited by the previouslyrandomly-oriented fibers of the first nonwoven layer 210A and the secondnonwoven layer 250A, define the first plurality of discontinuities 235and the second plurality of discontinuities 275, respectively. Each ofthe first plurality of discontinuities 235 and the second plurality ofdiscontinuities 275 exhibit a linearity that can be described as havinga longitudinal axis generally parallel to longitudinal axis L (shown inFIG. 3) of the cap 230 and tuft 270.

With regard to FIG. 2B, a nonwoven web 200B may comprise a firstnonwoven layer 210B which is constructed similar to the first nonwovenlayer 210A but may additionally comprise a first plurality of apertures225. The nonwoven web 200B may be constructed similar to the nonwovenweb 200A except as provided with regard to the first nonwoven layer210B. Similarly, with regard to FIG. 2C, a nonwoven web 200C maycomprise the first nonwoven layer 210B and a second nonwoven layer 250Bwhich comprises a second plurality of apertures 265. The second nonwovenlayer 250B may otherwise be constructed similar to the second nonwovenlayer 250A. The nonwoven web 200C may be constructed similar to thenonwoven web 200A and 200B except as provided with regard to the secondnonwoven layer 250B. Additional embodiments are contemplated where thesecond nonwoven layer 250B comprises apertures in the absence ofapertures in the first nonwoven layer 210A.

Referring again to FIGS. 2B-2C, the nonwoven webs 200B and 200C, thesecond plurality of fibers of the second nonwoven layers 250A and 250Bcan be in liquid communication with a first plurality of apertures 225in the first nonwoven layer 210B and/or can be in liquid communicationwith the first nonwoven layer 210B. In some embodiments, at least aportion of the second plurality of apertures 265 may be substantiallyaligned with the first plurality of apertures 225 in the first nonwovenlayer 210B.

The first nonwoven layer 210B and the second nonwoven layer 250B may bejoined about the periphery of each of the first plurality of apertures225. For example, for those embodiments where apertures are created bymelting fibers of the first nonwoven layer 210B or the first nonwovenlayer 210B together with the second nonwoven layer 250B, a bond may becreated between the first nonwoven layer 210B and the second nonwovenlayer 250B where the constituent fibers were melted. In someembodiments, the first nonwoven layer 210B and the second nonwovenlayers 250A or 250B are attached to one another about at least a portionof the periphery of each of the first plurality of apertures 225. Insome embodiments, the first nonwoven layer 210B and the second nonwovenlayer 250B are attached to one another about at least a portion of theperiphery of each of the second plurality of apertures 265. The secondnonwoven layer 250A may be joined about the periphery of each of thefirst plurality of apertures 225 of the first nonwoven layer 210B.

While the first nonwoven layer 210A, the second nonwoven layer 250A, andthe nonwoven web 200A are referenced below, the disclosure below isapplicable for the nonwoven webs 200B, 200C, and first nonwoven layer210B and second nonwoven layer 250B unless otherwise expressly stated.

Referencing FIGS. 3-6, caps 230 and tufts 270 alike can comprise aplurality of looped fibers that are substantially aligned such that eachof the caps 230 and tufts 270 have a distinct linear orientation and alongitudinal axis L. By “looped” fibers it is meant to refer to fibersof the caps 230 that are integral with and begin and end in the firstnonwoven layer 210A but extend generally outwardly in the Z-directionfrom the first surface 215 of the first nonwoven layer 210A. Similarly,“looped” fibers with regard to tufts 270 is meant to refer to fibers ofthe tufts 270 that are integral with and begin and end in the secondnonwoven layer 250A but extend generally outwardly in the Z-directionfrom the first surface 255 of the second nonwoven layer 250A and extendbeyond the first surface 215 of the first nonwoven layer 210A. By“aligned”, it is meant that looped fibers are all generally orientedsuch that, if viewed in plan view as in FIG. 5, each of the loopedfibers has a significant vector component parallel to a transverse axisT, and can have a major vector component parallel to the transverse axisT. The transverse axis T is generally orthogonal to longitudinal axis Lin the MD-CD plane and the longitudinal axis L is generally parallel tothe MD.

While the looped fibers of caps 230 are not shown as are the loopedfibers 408 of the tufts 270, the looped fibers of the caps 230 may besimilarly disposed as with regard to the looped fibers 408 of the tufts270 except that as shown the looped fibers of the caps 230 may bedisposed superjacent to the looped fibers of the tufts 270. As such,reference to the looped fibers herein shall be applicable to the loopedfibers of the caps 230 and the looped fibers of the tufts 270 unlessotherwise noted.

As used herein, a looped fiber 408 oriented at an angle of greater than45 degrees from the longitudinal axis L when viewed in plan view, as inFIG. 5, can have a significant vector component parallel to thetransverse axis T. As used herein, a looped fiber 408 oriented at anangle of greater than 60 degrees from longitudinal axis L when viewed inplan view, can have a major vector component parallel to the transverseaxis T. In some embodiments, at least 50%, at least 70%, and at least90% of looped fibers 408 of tuft 270 have a significant or a majorvector component parallel to transverse axis T. Fiber orientation can bedetermined by use of magnifying means if necessary, such as a microscopefitted with a suitable measurement 45 scale. In general, for anon-linear segment of fiber viewed in plan view, a straight-lineapproximation for both longitudinal axis L and the looped fibers 408 canbe used for determining angle of looped fibers 408 from longitudinalaxis L. For example, as shown in FIG. 5, one fiber 408A is shownemphasized by a heavy line, and its linear approximation 408B is shownas a dashed line. This fiber makes an angle of approximately 80 degreeswith the longitudinal axis (measured counterclockwise from L).

In one embodiment, tufts 270 may be spaced apart from adjacent tufts270, and similarly caps 230 may be spaced apart from adjacent caps 230.In some embodiments, each of the spaced apart tufts 270 and/or spacedapart caps 230 have generally parallel longitudinal axes L. The numberof tufts 270 and/or caps 230 per unit area of a nonwoven web of thepresent invention, i.e., the area density of tufts 270 and/or caps 230,can be varied from one tuft per unit area, e.g., square centimeter to ashigh as 100 tufts per square centimeter or similarly with regard to caps230. There can be at least 10, or at least 20 tufts 270 and/or caps 230per square centimeter, depending on the end use. In general, the areadensity need not be uniform across the entire area of nonwoven webs ofthe present invention, and, in some embodiments, tufts 270 and/or caps230 can be only in certain regions of nonwoven webs of the presentinvention, such as in regions having predetermined shapes, such aslines, stripes, bands, circles, and the like. In some embodiments, tufts270 and/or caps 230 can be spaced sufficiently closely so as toeffectively cover the first surface 215 of the first nonwoven 210A.

Tufts 270 are, in a sense, “punched above” the first nonwoven 210A andcan be “locked” in place by frictional engagement with discontinuities235 of the second surface 220. In some embodiments, for example, thelateral width of a discontinuity 235 (i.e., the dimension measuredparallel to its transverse axis) can be less than the maximum width ofthe tooth that formed the discontinuity (per the process describedbelow). This indicates a certain amount of recovery at the discontinuitythat tends to constrain tuft 270 from pulling back out throughdiscontinuity 235. The frictional engagement of the tufts 270 anddiscontinuities 235 can provide a structure having permanent tufting onone side that can be formed without adhesives or thermal bonding. Thistufting can provide a softness benefit to the user of the articleincorporating the nonwoven web.

While the embodiments described with regard to FIGS. 2A-2C, havelongitudinal axes L of tufts 270 and/or caps 230 generally aligned inthe MD, tufts 270 and/or caps 230 and, therefore, longitudinal axes L,can, in principle, be aligned in any orientation with respect to the MDor CD. Therefore, in general, it can be said that for each tuft 270and/or cap 230, the looped aligned fibers 408 (shown in FIGS. 3 and 4)are aligned generally orthogonal to the longitudinal axis L such thatthey have a significant vector component parallel to transverse axis T,and can have a major vector component parallel to transverse axis T.

Referring again to FIGS. 3 and 4, in some embodiments, as describedbelow, another characteristic of tufts 270 can be their generally openstructure characterized by open void area 433 defined interiorly oftufts 270. The void area 433 may have a shape that is wider or larger ata distal portion 431 of the tuft 270 and narrower at the tuft base 417of the tuft 270. This is opposite to the shape of the tooth which isused to form the tuft 270 which is discussed hereafter. The term “voidarea” is not meant to refer to an area completely free of any fibers.Rather, the term is meant as a general description of the generalappearance of tufts 270. Therefore, it may be that in some tufts 270 anon-looped fiber 418 or a plurality of loose non-looped fibers 418 maybe present in the void area 433. By “open” void area is meant that thetwo longitudinal ends of tuft 270 are generally open and free of fibers,such that tuft 270 can form something like a “tunnel” structure in anuncompressed state, as shown in FIG. 4. Generally, discontinuities 275at the tuft base 417 are narrow. The closing or narrowing or squeezingof other fibers at the tuft base 417 can help to stabilize the tufts270. The general shape of the caps 230 may be similar to that of thetufts 270; however, as shown in FIGS. 2A-2C, void space of a cap 230 maybe occupied, in part, by a tuft 270.

Due to the nature of many nonwoven webs useful as second nonwoven layer250A (shown in FIG. 2A) discontinuities 275 may not be as distinctlynoticeable as tufts 270. For this reason, the discontinuities 275 on thesecond surface 260 of the second nonwoven layer 250A can go unnoticedand may be generally undetected unless nonwoven web 200A (shown in FIG.2A) is closely inspected. As such, the second surface 260 of the secondnonwoven 250A can have the look and feel of an un-tufted first nonwovenlayer. Thus in some embodiments, nonwoven webs 200A can have thetextured look and feel of terry cloth on one surface, and a relativelysmooth, soft look and feel on second surface. In other embodiments,discontinuities 275 can appear as apertures, and may be aperturesthrough the second nonwoven 250A via the ends of the tunnel-like tufts270.

Looped fibers 408 and/or non-looped fibers 418 of tuft 270 can originateand extend from either the first surface 255 or the second surface 260of second nonwoven layer 250A. Of course the looped fibers 408 ornon-looped fibers 418 of tuft 270 can also extend from an interior ofsecond nonwoven layer 250A. In general, with regard to tufts 270, thelooped fibers 408 and non-looped fibers 418 comprise fibers that areintegral with and extend from the fibers of the second nonwoven layer250A.

Similarly, caps 230 may comprise looped fibers and/or non-looped fiberswhich originate and extend from either the first surface 215 or thesecond surface 220 of the first nonwoven layer 210A. The looped fibersand/or non-looped fibers may also extend from an interior of the firstnonwoven layer 210A. The looped fibers and/or non-looped fibers of thecaps 230 are integral with and extend from the fibers of the firstnonwoven layer 210A.

In some embodiments, the extension and/or urging of looped fibers 408and non-looped fibers 418 can be accompanied by a general reduction infiber cross sectional dimension (e.g., diameter for round fibers) due toplastic deformation of the fibers and Poisson's ratio effects.Therefore, the aligned looped fibers 408 of caps 230 and/or tufts 270can have a tuft average fiber diameter less than the average fiberdiameter of the fibers of the first nonwoven layer 210A and the secondnonwoven layer 250A, respectively. It is believed that this reduction infiber diameter can contribute to the perceived softness. Still in otherembodiments, the fibers/nonwoven material may be selected such thatthere is little to no reduction in fiber cross section when fibers areurged either in the Z-direction or negative Z-direction due to fibermobility. Embodiments are contemplated where the first and/or secondnonwoven layers are chosen to reduce the likelihood of thinning of thefibers and enhance fiber mobility.

Fiber-to-fiber mobility can be increased by reducing or eliminating thefiber-to-fiber bonds (e.g. with lower bond area or higher bond spacingor lower bond temperature in point bonded nonwovens or via reducedtemperature or air flow in through-air bonded nonwovens). Thermal bondscan be completely eliminated (i.e. avoided by not bonding) orsignificantly reduced in certain nonwoven webs to increasefiber-to-fiber mobility. Similarly, hydroentangled webs can be lessentangled to increase fiber-to-fiber mobility. For any web, lubricatingit prior to processing as disclosed herein can also increasefiber-to-fiber mobility. For example, a mineral oil or siliconelubricant can be applied. Additionally a slip agent or plasticizingagent can be added to some synthetic fiber webs, such as polyethylene orpolypropylene.

Referencing FIGS. 4 and 6, in some embodiments, the void space 433 oftufts 270 may comprise a first void space opening 451 which can be archshaped such that the first void space opening 451 is broadest proximalthe first surface 215 of the first nonwoven layer 210A and generallybecomes narrower towards the portion of the cap covering the distalportion 431 of the tuft 270. The cap 230 can have a cap base 471proximal the first surface 215 of the first nonwoven layer 210A, 210B.The cap base 471 can be narrower than a portion of the cap 230 away fromthe cap base 471. That is, the distance between extension locations 454can be less than maximum lateral extent of the cap 230 away (i.e. above)from the cap base 471. In some embodiments, the first void space opening451 can be uppercase omega shaped (Ω) such the first void space opening451 is narrower proximal the first surface 215 of the first nonwovenlayer 210A than at a location midway between the tuft base 417 and thedistal portion 431 of tuft 270. Similarly, if a second void spaceopening 452 is present, the second void space opening 452 can be archshaped such that the second void space opening 452 is broadest proximalthe first surface 215 of the first nonwoven layer 210A and generallynarrows towards the portion of the cap 230 covering the distal portion431 of the tuft 270. The second void space opening 452 can be uppercaseomega shaped (Ω) such that the second void space opening 452 is narrowerproximal the first surface 215 of the first nonwoven layer 210A than ata location midway between the tuft base 417 and the distal portion 431of tuft 270. The second void space opening 452 can oppose the first voidspace opening 451 in that at least part of the tuft 270 is betweensecond void space opening 452 and first void space opening 451. Thefirst void space opening 451, the second void space opening 452, and anyadditional openings can make the nonwoven web 200A liquid pervious. Insome forms, the tufts 270 and/or caps 230 may have a shape which issimilar to an inverted capital “U”-specifically for those forms wherethe tufts 270 and/or caps 230 are provided in the positive Z-direction.In other forms, where the tufts and/or caps are provided in the negativeZ-direction, the tufts and/or caps may have the shape of a capital “U”.The “U” shaped tufts and/or caps may appear like a plurality of bumps onthe web.

If there is a first void space opening 451 and a second void spaceopening 452, the cap 230 can integrally extend from the first nonwovenlayer 210A at at least two extension locations 454 spaced apart from oneanother by the first void space opening 451 and second void spaceopening 452. The at least two extension locations 454 can be at opposingpositions on opposing sides of the tuft 270. The cap 230 can integrallyextend from the first nonwoven layer 210A at at least two extensionlocations 454.

Caps of the present invention are thought to mask or partially maskfluid that is collected by the nonwoven web and remains in thecapillaries between fibers 408 of the tufts. Such a nonwoven webemployed in an absorbent article such as a wipe, a sanitary napkin, atampon, or a diaper can be appealing to the user (or caregiver) in thatpotentially unsightly fluids retained in the capillaries between fibers408 of the tufts will be obscured or partially obscured from the viewer.The caps cover or partially cover tufts in which fluids can be held andcan make the nonwoven web appear less soiled.

Embodiments including additional arrangements of caps and/or tufts areprovided with respect to FIGS. 7-9. With regard to FIG. 7, a nonwovenweb 700 is shown which comprises a first nonwoven layer 710 and a secondnonwoven layer 750. The first nonwoven layer 710 comprises a generallyplanar first surface 715 and a generally planar second surface 720opposed to the first surface 715, and the second nonwoven layer 750 hasa generally planar first surface 755 and a generally planar secondsurface 760. The first nonwoven layer 710 comprises a first plurality ofsubstantially randomly oriented fibers, and the second nonwoven layer750 comprises a second plurality of substantially randomly orientedfibers. At least a portion of the second plurality of fibers in thesecond nonwoven layer 750 is in liquid communication with the firstnonwoven layer 710. Similar to the first nonwoven layer 110 and secondnonwoven layers 150A and 150B (shown in FIGS. 1A and 1B), the respectivesurfaces of the first nonwoven layer 710 and second nonwoven layer 750,can be arranged such that the first surfaces 715 and 755, respectively,are body-facing surfaces, and the second surfaces 720 and 760,respectively, can be arranged as garment-facing surfaces.

While the embodiment shown in FIG. 7 depicts the first nonwoven layer710 having a first plurality of apertures 725 and the second nonwovenlayer 750 with a second plurality of apertures, these are optional. Forexample, embodiments are contemplated where the first nonwoven layer 710comprises the first plurality of apertures 725 while the second nonwovenlayer 750 does not comprise apertures. As another example, the secondnonwoven layer 750 may comprise the second plurality of apertures 765while the first nonwoven layer 710 does not comprise apertures.Additional embodiments are contemplated where both the first nonwovenlayer 710 and the second nonwoven layer 750 are sans apertures.

As shown, in some embodiments, the second surface 720 of the firstnonwoven layer 710 may comprise a first plurality of discontinuities735. The first plurality of discontinuities 735 are formed whenlocalized areas of constituent fibers of the first nonwoven layer 210Aare urged in the Z-direction such that these constituent fibers aredisposed superjacent to the first surface 715 of the first nonwovenlayer 710. However, instead of forming a cap 230 (shown in FIGS. 2A-2Cand 3-6), the urging in the Z-direction of the constituent fibers of thefirst nonwoven layer 710 may be such that a plurality of fibers breakthereby forming the first plurality of discontinuities 735.

As shown, in some embodiments, the second surface 760 of the secondnonwoven layer 750 may comprise a second plurality of discontinuities775 which may be configured as described with regard to the secondplurality of discontinuities 275 (shown in FIGS. 2A-2C and 3-4). Namely,localized areas of constituent fibers of the second nonwoven layer 750are urged in the Z-direction such that these constituent fibers aredisposed superjacent to the first surface 755 of the second nonwovenlayer 750. This Z-direction urging also forces these constituent fibersto extend through the first plurality of discontinuities 735 in thesecond surface 720 of the first nonwoven layer 710. The extension of theconstituent fibers of the second nonwoven layer 750 forms tufts 770.

Tufts 770 extend through at least a portion of the first plurality ofdiscontinuities 735 in the first nonwoven layer 710. Tufts 770 may beconfigured as described herein with regard to tufts 230 (shown in FIGS.2A-2C and 3-4). As shown, in some embodiments, tufts 770 may beuncovered by a corresponding cap formed by the constituent fibers of thefirst nonwoven layer 710.

With regard to FIG. 8, a nonwoven web 800 constructed in accordance withthe present invention is shown. The nonwoven web 800 may comprise afirst nonwoven layer 810 having a generally planar first surface 815 anda generally planar second surface 820 opposed to the first surface 815and a second nonwoven layer 850 having a generally planar first surface855 and a generally planar second surface 860. The first nonwoven layer810 comprises a first plurality of substantially randomly orientedfibers, and the second nonwoven layer 850 comprises a second pluralityof substantially randomly oriented fibers. At least a portion of thesecond plurality of fibers in the second nonwoven layer 850 is in liquidcommunication with the first nonwoven layer 810. Similar to the firstnonwoven layer 110 and second nonwoven layers 150A and 150B (shown inFIGS. 1A and 1B), the respective surfaces of the first nonwoven layer810 and second nonwoven layer 850, can be arranged such that the firstsurfaces 815 and 855, respectively, are body-facing surfaces, and thesecond surfaces 820 and 860, respectively, can be arranged asgarment-facing surfaces.

While the embodiment shown in FIG. 8 depicts the first nonwoven layer810 having a first plurality of apertures 825 and the second nonwovenlayer 850 with a second plurality of apertures, these are optional. Forexample, embodiments are contemplated where the first nonwoven layer 810comprises the first plurality of apertures 825 while the second nonwovenlayer 750 does not comprise apertures. As another example, the secondnonwoven layer 850 may comprise the second plurality of apertures 865while the first nonwoven layer 810 does not comprise apertures.Additional embodiments are contemplated where both the first nonwovenlayer 810 and the second nonwoven layer 850 are sans apertures.

As shown, in some embodiments, the first surface 815 of the firstnonwoven layer 810 may comprise a first plurality of discontinuities835. The first plurality of discontinuities 835 are formed whenlocalized areas of constituent fibers of the first nonwoven layer 810are urged in the negative Z-direction such that these constituent fibersare disposed subjacent to the first surface 815 of the first nonwovenlayer 810 thereby forming tufts 870. In some embodiments, the tufts 870may extend beyond the second surface 860 of the second nonwoven layer850 such that at least a portion of the tuft 870 is subjacent to thesecond surface 860.

The second nonwoven layer 850 may comprise a second plurality ofdiscontinuities 875. As shown, in some embodiments, the plurality oftufts 870 may extend through the second plurality of discontinuities875. The second plurality of discontinuities 875 may be created whenlocalized areas of constituent fibers of the second nonwoven layer 850are urged in the negative Z-direction such that these constituent fibersare disposed subjacent to the first surface 855 of the second nonwovenlayer 850. However, instead of forming a cap 230 (shown in FIGS. 2A-2Cand 3-6), the urging in the Z-direction of the constituent fibers of thesecond nonwoven layer 850 may be such that a plurality of fibers breakthereby forming the second plurality of discontinuities 875.

Tufts 870 extend through at least a portion of the second plurality ofdiscontinuities 875 in the second nonwoven layer 850. For example, tufts870 may extend through at least one of the plurality of discontinuities875 in the second surface 860 of the second nonwoven layer 850. Tufts870 may be configured as described herein with regard to tufts 230(shown in FIGS. 2A-2C and 3-4). As shown, in some embodiments, tufts 870may be uncovered by a corresponding cap formed by the constituent fibersof the second nonwoven layer 860. The nonwoven web 800 can provide asoftness benefit as well as improve fluid communication to an absorbentcore of a disposable absorbent article incorporating such nonwoven web800.

With regard to FIG. 9, nonwoven web 900, constructed in accordance withthe present invention, is shown. The nonwoven web 900 may comprise afirst nonwoven layer 910 having a generally planar first surface 915 anda generally planar second surface 920 opposed to the first surface 915and a second nonwoven layer 950 having a generally planar first surface955 and a generally planar second surface 960. The first nonwoven layer910 comprises a first plurality of substantially randomly orientedfibers, and the second nonwoven layer 950 comprises a second pluralityof substantially randomly oriented fibers. At least a portion of thesecond plurality of fibers in the second nonwoven layer 950 is in liquidcommunication with the first nonwoven layer 910. Similar to the firstnonwoven layer 910 and second nonwoven layers 150A and 150B (shown inFIGS. 1A and 1B), the respective surfaces of the first nonwoven layer910 and second nonwoven layer 950, can be arranged such that the firstsurfaces 915 and 955, respectively, are body-facing surfaces, and thesecond surfaces 920 and 960, respectively, can be arranged asgarment-facing surfaces.

While the embodiment shown in FIG. 9 depicts the first nonwoven layer910 having a first plurality of apertures 925 and the second nonwovenlayer 950 with a second plurality of apertures 965, these are optional.For example, embodiments are contemplated where the first nonwoven layer910 comprises the first plurality of apertures 925 while the secondnonwoven layer 950 does not comprise apertures. As another example, thesecond nonwoven layer 950 may comprise the second plurality of apertures965 while the first nonwoven layer 910 does not comprise apertures.Additional embodiments are contemplated where both the first nonwovenlayer 910 and the second nonwoven layer 950 are sans apertures.

As shown, in some embodiments, the first surface 955 of the secondnonwoven layer 950 may comprise a second plurality of discontinuities975. The second plurality of discontinuities 975 are formed whenlocalized areas of constituent fibers of the second nonwoven layer 950are urged in the negative Z-direction such that these constituent fibersare disposed subjacent to the second surface 960 of the second nonwovenlayer 950. The disposition of the constituent fibers, may, in someembodiments, form a cap 930. The second nonwoven layer 950 may comprisea plurality of caps 930 extending below the second surface 960. Each ofthe plurality of caps 930 can partially overlie at least one of thesecond plurality of discontinuities 975. For example, a first cap atleast partially overlies a first discontinuity, and a second cap atleast partially overlies a second discontinuity and so on.

Similarly, in some embodiments, the first surface 915 of the firstnonwoven layer 910 may comprise a first plurality of discontinuities935. The first plurality of discontinuities 935 can be formed whenlocalized areas of constituent fibers of the first nonwoven layer 910are urged in the negative Z-direction such that these constituent fibersare disposed subjacent to the second side 920 of the first nonwovenlayer 910. This negative Z-direction urging also forces theseconstituent fibers to extend through the second plurality ofdiscontinuities 975 in the first surface 955 of the second nonwovenlayer 950. The extension of the constituent fibers of the first nonwovenlayer 910 forms tufts 970.

Tufts 970 extend through at least a portion of the second plurality ofdiscontinuities 975 in the second nonwoven layer 950. Tufts 970 may beconfigured similarly as described with regard to tufts 270 (shown inFIGS. 2A-2C and 3-4).

Additionally, embodiments are contemplated where the nonwoven webcomprises a single nonwoven layer which is provided with an additive.The additive, similar to the embodiments above, can be provided to thenonwoven as part of the master batch or may be applied post fiberproduction via spraying, slot coating or the like. The single nonwovenlayer may be subjected to processing as described herein. For example,the single nonwoven layer may have a portion of its fibers urged in aZ-direction and/or urged in a negative Z-direction. In conjunction withthe Z-direction urging and/or negative Z-direction urging, orindependently therefrom, the single nonwoven layer may also comprise aplurality of apertures. The single nonwoven layer may comprise multiplenonwoven substrates as described hereafter.

Nonwoven Web Processing

Depending on the orientations of caps and tufts described heretofore,processing of nonwoven webs of the present invention can vary. Referringto FIG. 10, there is shown an apparatus 1000 and method for producingthe nonwoven webs of the present invention. The apparatus 1000 comprisesa pair of intermeshing rolls 1002 and 1004, each rotating about an axisA—the axes A being parallel and in the same plane. Roll 1002 comprises aplurality of ridges 1006 and corresponding grooves 1008 which extendunbroken about the entire circumference of roll 1002.

Roll 1004 is similar to roll 1002, but rather than having ridges thatextend unbroken about the entire circumference, roll 1004 comprises aplurality of rows of circumferentially-extending ridges that have beenmodified to be rows of circumferentially-spaced teeth 1010 that extendin spaced relationship about at least a portion of roll 1004. Theindividual rows of teeth 1010 of roll 1004 are separated bycorresponding grooves 1012. In operation, rolls 1002 and 1004 intermeshsuch that the ridges 1006 of roll 1002 extend into the grooves 1012 ofroll 1004 and the teeth 1010 of roll 1004 extend into the grooves 1008of roll 1002. A nip 1016 is formed between the counter-rotatingintermeshing rolls 1002 and 1004. Both or either of rolls 1002 and 1004can be heated by means known in the art such as by using hot oil filledrollers or electrically-heated rollers.

The apparatus 1000 is shown in a configuration having one patternedroll, e.g., roll 1004, and one non-patterned grooved roll 1002. However,in certain embodiments it may be preferable to use two patterned rollssimilar to roll 1004 having either the same or differing patterns, inthe same or different corresponding regions of the respective rolls.Such an apparatus can produce webs with tufts protruding from both sidesof the nonwoven web.

Nonwoven webs of the present invention can be made by mechanicallydeforming the first nonwoven layer 210A and the second nonwoven layer250A that can each be described as generally planar and two dimensionalprior to processing by the apparatus shown in FIG. 10. By “planar” and“two dimensional” is meant simply that the webs start the process in agenerally flat condition relative to the finished nonwoven web 200A thathas distinct, out-of-plane, Z-direction three-dimensionality due to theformation of tufts 270 and/or caps 230. “Planar” and “two-dimensional”are not meant to imply any particular flatness, smoothness ordimensionality. Additionally, nonwoven web 700 (shown in FIG. 7) can beprocessed as described above.

The nonwoven webs 800 and 900 (shown in FIGS. 8 and 9, respectively) canbe processed as described above with some variation described hereafter.For example, in order to accomplish the negative Z-direction urging asdescribed herein, the nonwoven layers may be provided to the apparatus1000 such that the second nonwoven layer 850 or 950 is disposedsuperjacent to the first nonwoven layer 810 or 910. However, flippingthe resultant nonwoven web at rapid production speeds for processing isdifficult to manage and would introduce much complexity into theproduction of such nonwoven webs. In some embodiments, particularly forthose where the desired resultant nonwoven web is as described withregard to nonwoven webs 800 and 900, the rolls 1002 and 1004 ofapparatus 1000 can be inverted. For example, the patterned roll 1004 maybe positioned superjacent to the non-patterned grooved roll 1002.

The number, spacing, and dimensions of tufts and/or caps can be variedto give varying texture to nonwoven webs of the present invention. Forexample, if tufts and/or caps are sufficiently closely spaced theresultant nonwoven web can have a terry cloth-like feel. Alternatively,tufts and/or caps can be arranged in patterns such as lines or filledshapes to create portions of a web having greater texture, softness,bulk, absorbency or visual design appeal. For example, when tufts and/orcaps are arranged in a pattern of a line or lines, the tufts and/or capscan have the appearance of stitching. Likewise, the size dimensions,such as the height, length and width of individual tufts can be varied.

Single tufts and/or caps can be as long as about 3 cm in length and canbe made alone or dispersed among tufts and/or caps of various sizes. Insome embodiments, the tufts and/or caps may have a length ranging fromabout 1 mm to about 10 mm. In some embodiments, the tufts and/or capsmay have a length ranging from about 2 mm to about 8 mm; from about 3 mmto about 7 mm, or any ranges within the values recited or any numberswithin the values recited.

Additionally, embodiments are contemplated where a nonwoven web includesa plurality of tufts and/or caps which are configured differently. Forexample, a nonwoven web of the present invention may comprise a tuft 270and a cap 230 (shown in FIGS. 2A-2C) in a first area of the nonwoven weband may comprise a tuft 770 (shown in FIG. 7) in a second area of thenonwoven web. In other embodiments, a nonwoven web may comprise a tuft770 (shown in FIG. 7) in a first area of a nonwoven web and may comprisea tuft 970 and a cap 930 (shown in FIG. 9) in a second area of thenonwoven web. In other embodiments, a nonwoven web may comprise a tuft770 (shown in FIG. 7) in a first area of the nonwoven web and a tuft 870(shown in FIG. 8) in a second area of the nonwoven web. In otherembodiments, a nonwoven web may comprise a tuft 270 and a cap 230 (shownin FIGS. 2A-2C) in a first area of the nonwoven web and a tuft 870(shown in FIG. 8) in a second area of the nonwoven web. In someembodiments, a nonwoven web may comprise a tuft 270 and a cap 230 (shownin FIGS. 2A-2C) in a first area of the nonwoven web and a tuft 970 and acap 930 (shown in FIG. 9) in a second area of the nonwoven web. Still inother embodiments, a nonwoven web may comprise a tuft 970 and a cap 930(shown in FIG. 9) in a first area of the nonwoven web and may comprise atuft 870 (shown in FIG. 8) in a second area of the nonwoven web.Nonwoven webs of the present invention may utilize any and allcombinations of the tufts and/or caps described with regard to FIGS.2A-2C, 7, 8, and 9) in accordance with the foregoing embodiments, e.g.first area with first set of tufts and/or caps, second area with secondset of tufts and/or caps, third area with third set of tufts and/orcaps, and so on, wherein each of the first, second and third sets oftufts and/or caps are different.

While the first nonwoven layer and the second nonwoven layer arereferred to as 210A and 250A, it should be understood that any of thefirst nonwoven layers and second nonwoven layers described herein may beprocessed similarly. The first nonwoven layer 210A and the secondnonwoven layer 250A are provided either directly from their respectiveweb making processes or indirectly from supply rolls (neither shown) andmoved in the machine direction to the nip 1016 of counter-rotatingintermeshing rolls 1002 and 1004. The first nonwoven layer 210A and thesecond nonwoven layer 250A are preferably held in a sufficient webtension so as to enter the nip 1016 in a generally flattened conditionby means well known in the art of web handling. As each of the firstnonwoven layer 210A and the second nonwoven layer 250A goes through thenip 1016, the teeth 1010 of roll 1004—which are intermeshed with grooves1008 of roll 1002—simultaneously urge fibers of the first nonwoven layer210A out of the plane of the first nonwoven layer 210A thereby formingcaps 230 and urge fibers of the second nonwoven layer 250A out of theplane of the second nonwoven layer 250A and through the plane of thefirst nonwoven layer 210A to form tufts 270.

The number, spacing, and size of tufts 270 and/or caps 230 (shown inFIGS. 3 and 4) can be varied by changing the number, spacing, and sizeof teeth 1010 and making corresponding dimensional changes as necessaryto roll 1004 and/or roll 1002. This variation, together with thevariation possible in first nonwoven layer 210A and the second nonwovenlayer 250A permits many varied nonwoven webs 200A to be made for manypurposes. The size of teeth as well as additional details regardingprocessing of nonwovens and laminates comprising nonwovens can be foundin U.S. Pat. Nos. 7,410,683; 7,789,994; 7,838,099; 8,440,286; and8,697,218.

As stated previously, the first nonwoven layer and the second nonwovenlayer, as described herein, may be provided as discrete layers. Forexample, embodiments are contemplated where the first nonwoven layer isderived from a first supply roll having a first specific fiber makeupwhile the second nonwoven layer is derived from a second supply rollhaving a second specific fiber makeup. In some embodiments, the fibermakeup between the first supply roll and the second supply roll can bedifferent as described below.

Embodiments are contemplated where the first nonwoven layer and thesecond nonwoven layer are both spunbonded nonwoven materials. In someembodiments, the first nonwoven and the second nonwoven are produced bydifferent spin beams on a single spunbond nonwoven manufacturing line.As used herein, “spunbond fibers” refers to small diameter fibers whichare formed by extruding molten thermoplastic material as filaments froma plurality of fine, usually circular capillaries of a spinneret withthe diameter of the extruded filaments then being rapidly reduced.Spunbond fibers are generally not tacky when they are deposited on acollecting surface. Spunbond fibers are generally continuous and haveaverage diameters (from a sample of at least 10) larger than 7 microns,and more particularly, between about 8 and 40 microns. For example, thefirst nonwoven layer may be produced by a first spin beam while thesecond nonwoven layer is produced by a second spin beam.

In some embodiments, the first nonwoven layer and/or the second nonwovenlayer may comprise meltblown nonwoven materials. In some embodiments,the first nonwoven layer and/or the second nonwoven layer may comprisefiner fibers, including fibers with average diameters less than onemicron or 1000 nanometers (an “N-fiber”), may comprise meltfibrillation, advanced meltblowing technology, or electrospinning.Advanced melt-blowing technology is described, for example, in U.S. Pat.No. 4,818,464 to Lau, U.S. Pat. No. 5,114,631 to Nyssen et al., U.S.Pat. No. 5,620,785 to Watt et al., and U.S. Pat. No. 7,501,085 toBodaghi et al. Melt film fibrillation technology, as example of meltfibrillation, is a general class of making fibers defined in that one ormore polymers are molten and are extruded into many possibleconfigurations (e.g., hollow tubes of films, sheets of films,co-extrusion, homogeneous or bi-component films or filaments) and thenfibrillated or fiberized into filaments. Examples of such processes aredescribed in U.S. Pat. No. 4,536,361 to Torobin, U.S. Pat. No. 6,110,588to Perez et al., U.S. Pat. No. 7,666,343 to Johnson et al., U.S. Pat.No. 6,800,226 to Gerking. Electrospinning processes useful to make finefibers are described in U.S. Pat. No. 1,975,504 to Formhals et al., U.S.Pat. No. 7,585,437, to Jirsak et al., U.S. Pat. No. 6,713,011 to Chu etal., U.S. Pat. No. 8,257,641 to Qi et al.; and also in“Electrospinning”, by A. Greiner and J. Wendorff, in Angew. Chem. Int.Ed., 2007, 46(30), 5670-5703.

In some embodiments, the first nonwoven layer and/or the second nonwovenlayer may comprise spunlaid or spunbond nonwoven materials. The spunlaidor spunbond fibers typically have an average diameter in the range ofabout 8 microns to about 40 microns, or a fiber titer in the range from0.5 to 10 denier. The meltblown fibers have a diameter of typically inthe range from 0.5 microns to 10 microns on average, or 0.001 denier to0.5 denier, and range from about 0.1 microns to over 10 microns. Finefibers range in average or median diameter from 0.1 microns to 2microns, and some fine fibers have a number-average diameter of lessthan about 1 micron, a mass-average diameter of less than about 1.5microns, and a ratio of the mass-average diameter to the number-averagediameter less than about 2.

Dry-Laid and Wet-Laid Nonwoven Substrates

In addition to nonwoven substrates made from the fiber spinningtechnologies of molten materials, the first nonwoven layer and/or thesecond nonwoven layer may be made by other means from pre-formed fibers(including natural fibers), such as by drylaid or wetlaid technologies.Drylaid technologies include carding and airlaying. These technologiesmay be combined with each other, e.g., drylaid with meltspun, to formmulti-layer, functional nonwoven substrates.

The carding process uses fibers cut into discrete lengths called staplefiber. The type of fiber and the desired end product propertiesdetermine the fiber length and denier. Typical staple fibers have alength in the range of 20 mm to 200 mm and a linear density in the rangeof 1 dpf to 50 dpf (denier per fiber), though staple fibers beyond thisrange have also been used for carding. The carding technology processesthese staple fibers into a formed substrate. Staple fibers are typicallysold in compressed bales that need to be opened to make uniform nonwovensubstrates. This opening process may be done through a combination ofbale opening, coarse opening, fine opening, or by a similar process.Staple fibers are often blended in order to mix different fiber typesand/or to improve uniformity. Fibers may be blended by blending fiberhoppers, bale openers, blending boxes, or by similar methods. The openedand blended fibers are transported to a chute that deposits the fibersacross the width of the card and with a density as uniform as practicalin order to make a nonwoven substrate with the desired basis weightuniformity. The card contains a series of parallel rollers and/or fixedplates that are covered with metallic clothing, rigid saw-toothed wireswith specific geometry that staple fibers are processed between. Cardingtakes place when fiber tufts transport between the tangent points of twosurfaces that have a differential surface speed and opposing angledirections on the metallic clothing. Cards may have a single maincylinder to card with or multiple cylinders. Cards may have a singledoffer or multiple doffers to remove the carded fibers and the cards maycontain randomizing rollers or condenser rollers to reduce the highlyisotropic orientation of the individual fibers in the web. The cardingprocess may contain a single card or multiple cards in line with oneanother, where the fibers of a subsequent card are deposited on top ofthe fibers from a preceding card and thus can form multiple layers,e.g., of different fiber compositions. The orientation of these cardsmay be parallel to the downstream operation or perpendicular to thedownstream operation by means of turning or cross-lapping.

The airlaid process also uses fibers of discrete length, though thesefibers are often shorter than the staple fibers used for carding. Thelength of fibers used in airlaying typically ranges from 2 mm to 20 mm,though lengths beyond this range may also be used. Particles may also bedeposited into the fibrous structure during the airlaying process. Somefibers for airlaying may be prepared similarly as for carding, i.e.,opening and blending as described above. Other fibers, such as pulp, mayuse mills, such as hammer mills or disc mills, to individualize thefibers. The various fibers may be blended to improve the uniformity ofproperties of the finished nonwoven substrate. The airlaying formingdevice combines external air and the fibers and/or particles so that thefibers and/or particles are entrained in the airsteam. Afterentrainment, the fibers and/or particles are collected as a loose webupon a moving foraminous surface, such as a wire mesh conveyor belt, forexample. The airlaying process may contain a single airlaying formingdevice or multiple airlaying forming devices in line with one another,where the fibers and/or particles of the subsequent airlaying formingdevice are deposited on top of the fibers and/or particles from apreceding airlaying forming device, thereby allowing manufacture of amulti-layered nonwoven substrate.

Wet-laid nonwovens are made with a modified papermaking process andtypically use fibers in the range of 2 mm to 20 mm, though lengthsbeyond this range have also been used. Some fibers for wetlaying may beprepared similarly as for carding, i.e., opening and blending asdescribed above. Other fibers, such as pulp, may use mills, such ashammer mills or disc mills, to individualize the fibers. The fibers aresuspended in water, possibly with other additives like bonding agents,and this slurry is typically added to a headbox from where it flows ontoa wetlaid forming device to create a sheet of material. After initialwater removal, the web is bonded and dried.

Spunlace nonwovens are typically carded and hydroentangled. The fibersof the spunlace nonwoven are first carded. In order to provide thecarded fibers with integrity in the Z-direction and in CD, the cardedfibers are then subjected to hydroentangling. Instead of cardednonwovens, spunlace nonwovens may be air-laid or wet-laid andsubsequently hydroentangled.

Embodiments are contemplated where the first nonwoven layer and/or thesecond nonwoven layer comprise a plurality of constituent nonwovensubstrates. For the examples below, spunbonded shall be referred to withan “S”; meltblown shall be referred to with an “M”; spunlace shall bereferred to with an “SL”; carded shall be referred to with a “C”; andfine fiber layers shall be referred to with an “N”. The first nonwovenlayer and/or the second nonwoven layer may comprise an S first substrateand an M second substrate. Additional substrates may be added forexample, an SMS structure may be created. In other examples, theconstituent substrates of the first nonwoven layer and/or the secondnonwoven layer may comprise an S and a C substrate; an S and SLsubstrates; an SNMS substrates or any combination thereof. In someembodiments, the first nonwoven layer and/or the second nonwoven layermay comprise a spunbond fine fiber laminate, “SNL”.

The constituent substrates of the first nonwoven layer and/or the secondnonwoven layer may be provided with structural integrity via a varietyof different processes. Some examples include thermal point bonding, airthrough bonding, hydroentangling, and needlepunching each of which iswell known in the art. Similarly, the attachment of the first nonwovenlayer to the second nonwoven layer may be achieved by a variety ofdifferent processes. Examples of such processes are discussed hereafter.

Embodiments are contemplated where the constituent substrates of thefirst nonwoven layer and the second nonwoven layer are subjected tosimilar attachment processes. For example, the constituent substrates ofthe first nonwoven layer and the second nonwoven layer may each besubjected to a hydroentangling process, a through air bonding process, aneedlepunching process, or a thermal bonding process. In suchembodiments, the attachment processes for the first nonwoven and/or thesecond nonwoven may be different. For example, the constituentsubstrates of the first nonwoven layer may be subjected to a firsthydroentangling process while the constituent substrates of the secondnonwoven layer are subjected to a second hydroentangling process. Thefirst hydroentangling process, in some embodiments, may provide a higherdegree of structural integrity in the first nonwoven layer versus thatprovided to the second nonwoven layer via the second hydroentanglingprocess. Alternatively, in some embodiments, the first hydroentanglingprocess may provide a lesser degree of structural integrity in the firstnonwoven layer versus that provided to the second nonwoven layer via thesecond hydroentangling process. Similar embodiments are contemplatedwith regard to through air bonding, needlepunching, and thermal pointbonding.

Additionally, embodiments are contemplated where the constituentsubstrates of the first nonwoven layer and the second nonwoven layer aresubjected to disparate forming or bonding processes. For example, theconstituent substrates of the first nonwoven layer may be subjected to ahydroentangling process while the constituent substrates of the firstnonwoven layer are subjected to a through air bonding process. Otherexamples include subjecting one of the first nonwoven layer or thesecond nonwoven layer to hydroentangling and the other nonwoven layer toneedlepunching, through air bonding, or thermal point bonding. Anotherexample includes subjecting one of the first nonwoven layer or thesecond nonwoven layer to needlepunching and the other nonwoven layer tothrough air bonding or thermal point bonding. Yet another exampleincludes subjecting one of the first nonwoven layer or the secondnonwoven layer to through air bonding and the other to thermal pointbonding. Embodiments are contemplated where the forming or bondingprocess of the first nonwoven layer provides a higher degree ofstructural integrity than that provided to the second nonwoven layer.Alternatively, embodiments are contemplated where the forming or bondingprocess of the first nonwoven layer provides a lesser degree ofstructural integrity than that provided to the second nonwoven layer.

It can be appreciated that in some embodiments, suitable first andsecond nonwoven layers should comprise fibers capable of experiencingsufficient plastic deformation and tensile elongation, or are capable ofsufficient fiber mobility, such that looped fibers 408 (shown in FIGS. 3and 4) are formed. However, it is recognized that a certain percentageof fibers urged out of the plane of the first surface of second nonwovenlayer will not form a loop, but instead will break and form loose ends.Such fibers are referred to herein as “loose” fibers or non-loopedfibers (i.e. loose fiber ends) 418 (shown in FIGS. 3 and 4).

In some embodiments, most or all of the fibers of tufts can benon-looped fibers. Non-looped fibers can also be the result of formingtufts from nonwoven webs consisting of, or containing, cut staplefibers. In such a case, some number of the staple fiber ends mayprotrude into the tuft, depending upon such things as the number ofstaple fibers in the web, the staple fiber cut length, and the height ofthe tufts. In some instances, it may be desired to use a blend of fibersof different lengths in a precursor web or fibers of different lengthsin different layers. This may be able to selectively separate the longerfibers from the shorter fibers. The longer fibers may predominately formthe tuft while the shorter fibers predominately remain in the portion ofthe web not forming the tuft. A mixture of fiber lengths can includefibers of approximately 2 to 8 centimeters for the longer fibers andless than about 1 centimeter for the shorter fibers.

Regarding the nonwoven webs 200A, 200B, and 200C (shown in FIGS. 2A-2C),for those embodiments where the nonwoven web is utilized as a topsheetfor a disposable absorbent article, it may be desirable to increase thelikelihood of the occurrence of non-looped fibers 418 in the caps. Theincrease of non-looped fibers 418 in the caps can increase the comfortto the wearer of the absorbent article. Accordingly, shorter fibers maybe utilized for the first nonwoven layer or in those areas of the firstnonwoven layer that will urged into caps than those of the secondnonwoven layer. Similarly, in some embodiments, the fibers of the firstnonwoven layer may be more capable of experiencing more plasticdeformation before fracturing than the fibers of the second nonwovenlayer. In some embodiments, a combination of the above approaches may beutilized with regard to the constituent fibers of the first nonwovenlayer versus the constituent fibers of the second nonwoven layer.

Similarly, with regard to FIG. 7, as the tuft 770 may form a portion ofthe user facing surface of a disposable absorbent article, appropriateselection of fibers for the second nonwoven layer 750 may be desirableto increase the likelihood of non-looped fibers 418 in the tufts 770.Additionally, non-looped fibers 418 may be beneficial for the nonwovenwebs 800 and 900 (shown in FIGS. 8 and 9). For example, since the tufts870 and 970 are oriented in the negative Z-direction, a large number ofnon-looped fibers 418 in the first nonwoven layer 810 or 910 mayincrease the permeability of the first nonwoven layer 810 or 910. Thisincrease in permeability may reduce the need for apertures or in someembodiments, fewer apertures may be required for adequate liquidtransfer to subjacent layers of a disposable absorbent article.

The first nonwoven layer and the second nonwoven layer, as discussedpreviously, comprise, in some embodiments, a plurality of randomlyoriented fibers. The plurality of randomly oriented fibers of the firstnonwoven layer and/or the second nonwoven layer may comprise anysuitable thermoplastic polymer.

Suitable thermoplastic polymers, as used in the disclosed compositions,are polymers that melt and then, upon cooling, crystallize or harden,but can be re-melted upon further heating. Suitable thermoplasticpolymers used herein have a melting temperature (also referred to assolidification temperature) from about 60° C. to about 300° C., fromabout 80° C. to about 250° C., or from 100° C. to 215° C. And, themolecular weight of the thermoplastic polymer should be sufficientlyhigh to enable entanglement between polymer molecules and yet low enoughto be melt spinnable.

In some embodiments, the thermoplastic polymers can be derived fromrenewable resources or from fossil minerals and oils. The thermoplasticpolymers derived from renewable resources are bio-based, for examplesuch as bio produced ethylene and propylene monomers used in theproduction polypropylene and polyethylene. These material properties areessentially identical to fossil based product equivalents, except forthe presence of carbon-14 in the thermoplastic polymer. Renewable andfossil based thermoplastic polymers can be combined together in thepresent invention in any ratio, depending on cost and availability.

Recycled thermoplastic polymers can also be used, alone or incombination with renewable and/or fossil derived thermoplastic polymers.The recycled thermoplastic polymers can be pre-conditioned to remove anyunwanted contaminants prior to compounding or they can be used duringthe compounding and extrusion process, as well as simply left in theadmixture. These contaminants can include trace amounts of otherpolymers, pulp, pigments, inorganic compounds, organic compounds andother additives typically found in processed polymeric compositions. Thecontaminants should not negatively impact the final performanceproperties of the admixture, for example, causing spinning breaks duringa fiber spinning process.

Some suitable examples of thermoplastic polymers include polyolefins,polyesters, polyamides, copolymers thereof, and combinations thereof. Insome embodiments, the thermoplastic polymer can be selected from thegroup consisting of polypropylene, polyethylene, polypropyleneco-polymer, polyethylene co-polymer, polyethylene terephthalate,polybutylene terephthalate, polylactic acid, polyhydroxyalkanoates,polyamide-6, polyamide-6,6, and combinations thereof. The polymer can bepolypropylene based, polyethylene based, polyhydroxyalkanoate basedpolymer systems, copolymers and combinations thereof.

In some embodiments, the thermoplastic polymers include polyolefins suchas polyethylene or copolymers thereof, including low density, highdensity, linear low density, or ultra low density polyethylenes suchthat the polyethylene density ranges between 0.90 grams per cubiccentimeter to 0.97 grams per cubic centimeter, between 0.92 and 0.95grams per cubic centimeter or any values within these ranges or anyranges within these values. The density of the polyethylene may bedetermined by the amount and type of branching and depends on thepolymerization technology and co-monomer type. Polypropylene and/orpolypropylene copolymers, including atactic polypropylene; isotacticpolypropylene, syndiotactic polypropylene, and combination thereof canalso be used. Polypropylene copolymers, especially ethylene can be usedto lower the melting temperature and improve properties. Thesepolypropylene polymers can be produced using metallocene andZiegler-Natta catalyst systems. These polypropylene and polyethylenecompositions can be combined together to optimize end-use properties.Polybutylene is also a useful polyolefin and may be used in someembodiments.

Other suitable polymers include polyamides or copolymers thereof, suchas Nylon 6, Nylon 11, Nylon 12, Nylon 46, Nylon 66; polyesters orcopolymers thereof, such as maleic anhydride polypropylene copolymer,polyethylene terephthalate; olefin carboxylic acid copolymers such asethylene/acrylic acid copolymer, ethylene/maleic acid copolymer,ethylene/methacrylic acid copolymer, ethylene/vinyl acetate copolymersor combinations thereof; polyacrylates, polymethacrylates, and theircopolymers such as poly(methyl methacrylates). Other nonlimitingexamples of polymers include polycarbonates, polyvinyl acetates,poly(oxymethylene), styrene copolymers, polyacrylates,polymethacrylates, poly(methyl methacrylates), polystyrene/methylmethacrylate copolymers, polyetherimides, polysulfones, or combinationsthereof. In some embodiments, thermoplastic polymers includepolypropylene, polyethylene, polyamides, polyvinyl alcohol, ethyleneacrylic acid, polyolefin carboxylic acid copolymers, polyesters, andcombinations thereof.

Biodegradable thermoplastic polymers also are contemplated for useherein. Biodegradable materials are susceptible to being assimilated bymicroorganisms, such as molds, fungi, and bacteria when thebiodegradable material is buried in the ground or otherwise contacts themicroorganisms (including contact under environmental conditionsconducive to the growth of the microorganisms). Suitable biodegradablepolymers also include those biodegradable materials which areenvironmentally-degradable using aerobic or anaerobic digestionprocedures, or by virtue of being exposed to environmental elements suchas sunlight, rain, moisture, wind, temperature, and the like. Thebiodegradable thermoplastic polymers can be used individually or as acombination of biodegradable or non-biodegradable polymers.Biodegradable polymers include polyesters containing aliphaticcomponents. Among the polyesters are ester polycondensates containingaliphatic constituents and poly(hydroxycarboxylic) acid. The esterpolycondensates include diacids/diol aliphatic polyesters such aspolybutylene succinate, polybutylene succinate co-adipate,aliphatic/aromatic polyesters such as terpolymers made of butylenesdiol, adipic acid and terephthalic acid. The poly(hydroxycarboxylic)acids include lactic acid based homopolymers and copolymers,polyhydroxybutyrate (PHB), or other polyhydroxyalkanoate homopolymersand copolymers. Such polyhydroxyalkanoates include copolymers of PHBwith higher chain length monomers, such as C₆-C₁₂, and higher,polyhydroxyalkanaotes, such as those disclosed in U.S. Pat. Nos. RE36,548 and 5,990,271.

An example of a suitable commercially available polylactic acid isNATUREWORKS from Cargill Dow and LACEA from Mitsui Chemical. An exampleof a suitable commercially available diacid/diol aliphatic polyester isthe polybutylene succinate/adipate copolymers sold as BIONOLLE 1000 andBIONOLLE 3000 from the Showa High Polymer Company, Ltd. (Tokyo, Japan).An example of a suitable commercially available aliphatic/aromaticcopolyester is the poly(tetramethylene adipate-co-terephthalate) sold asEASTAR BIO Copolyester from Eastman Chemical or ECOFLEX from BASF.

Non-limiting examples of suitable commercially available polypropyleneor polypropylene copolymers include Basell Profax PH-835 (a 35 melt flowrate Ziegler-Natta isotactic polypropylene from Lyondell-Basell), BasellMetocene MF-650W (a 500 melt flow rate metallocene isotacticpolypropylene from Lyondell-Basell), Polybond 3200 (a 250 melt flow ratemaleic anhydride polypropylene copolymer from Crompton), Exxon Achieve3854 (a 25 melt flow rate metallocene isotactic polypropylene fromExxon-Mobil Chemical), Mosten NB425 (a 25 melt flow rate Ziegler-Nattaisotactic polypropylene from Unipetrol), Danimer 27510 (apolyhydroxyalkanoate polypropylene from Danimer Scientific LLC), DowAspun 6811A (a 27 melt index polyethylene polypropylene copolymer fromDow Chemical), and Eastman 9921 (a polyester terephthalic homopolymerwith a nominally 0.81 intrinsic viscosity from Eastman Chemical).

Polypropylene can have a melt flow index of greater than 5 g/10 min, asmeasured by ASTM D-1238, used for measuring polypropylene. Othercontemplated melt flow indices for polypropylene include greater than 10g/10 min, greater than 20 g/10 min, or about 5 g/10 min to about 50 g/10min.

The thermoplastic polymer component can be a single polymer species asdescribed above or a blend of two or more thermoplastic polymers asdescribed above.

In some embodiments, the first nonwoven layer and second nonwoven layermay be fibrous woven or nonwoven webs comprising elastic or elastomericfibers. Elastic or elastomeric fibers can be stretched at least about50% and return to within 10% of their original dimension. Tufts can beformed from elastic fibers if the fibers are simply displaced due to themobility of the fiber within the nonwoven, or if the fibers arestretched beyond their elastic limit and are plastically deformed.

In some embodiments, the constituent fibers of the first nonwoven layercan be comprised of polymers such as polypropylene and blends ofpolypropylene and polyethylene. In some embodiments, the second nonwovenlayer may comprise fibers selected from polypropylene,polypropylene/polyethylene blends, and polyethylene/polyethyleneteraphthalate blends. In some embodiments, the second nonwoven layer maycomprise fibers selected from cellulose rayon, cotton, other hydrophilicfiber materials, or combinations thereof. The fibers can also comprise asuper absorbent material such as polyacrylate or any combination ofsuitable materials.

In one embodiment, the constituent fibers of the first nonwoven layerare selected such that the first nonwoven layer is hydrophobic, and theconstituent fibers of the second nonwoven layer are selected such thatthe second nonwoven layer is hydrophilic. For example, in someembodiments, the fibers of the first nonwoven layer may comprisepolypropylene, while the fibers of the second nonwoven layer compriserayon. In one specific embodiment, the fibers of the second nonwovenlayer comprise thermoplastic fibers that are treated with a topicalsurfactant or comprise a hydrophilic melt additive that blooms to thesurface in order to render the second nonwoven layer hydrophilic. Insuch embodiments, the second nonwoven layer may comprise the fibers asmentioned previously for the first nonwoven layer. Some examples ofsuitable hydrophilic treatments include Silastol PH26 available fromSchill & Seilacher or Stantex S6327 available from Pulcra Chemicals GmbHeach of which is a post fiber production hydrophilic treatment. Suitablehydrophilic melt additives are available from Polyvel, Inc. sold underthe trade name VW351 wetting agent and from Goulston Technologies Inc.under the trade name Hydrosorb 1001. Other suitable hydrophilicadditives are available from Techmer PM, LLC under the trade namesPPM15560, TPM12713, PPM19913, PPM19441, PPM 19914 (for polypropylene)and PPM19668 (for polyethylene). Additional examples of hydrophilicadditives whether as a master batch or post fiber production aredescribed in U.S. Patent Application No. 2012/0077886; U.S. Pat. Nos.5,969,026; and 4,578,414.

The fibers of the nonwoven layer and/or the second nonwoven layer can bemonocomponent, bi-component, and/or bi-constituent, round or non-round(e.g., capillary channel fibers), and can have major cross-sectionaldimensions (e.g., diameter for round fibers) ranging from 0.1-500microns. For example, one type of fibers suitable for the nonwoven webincludes nanofibers. Nanofibers are described as fibers having a meandiameter of less than 1 micron. Nanofibers can comprise all of thefibers in a nonwoven web or a portion of the fibers in a nonwoven web.The constituent fibers of the nonwoven precursor web may also be amixture of different fiber types, differing in such features aschemistry (e.g. polyethylene and polypropylene), components (mono- andbi-), denier (micro denier and >20 denier), shape (i.e. capillary andround) and the like. The constituent fibers can range from about 0.1denier to about 100 denier.

Embodiments are contemplated where the first plurality of fibers and/orthe second plurality of fibers comprise agents in addition to theirconstituent chemistry. For example, suitable additives include additivesfor coloration, antistatic properties, lubrication, hydrophilicity, andthe like and combinations thereof. These additives, for example titaniumdioxide for coloration, are generally present in an amount less thanabout 5 weight percent and more typically about 2 weight percent.

As used herein, the term “monocomponent” fiber refers to a fiber formedfrom one extruder using one or more polymers. This is not meant toexclude fibers formed from one polymer to which small amounts ofadditives have been added for coloration, antistatic properties,lubrication, hydrophilicity, etc.

As used herein, the term “bi-component fibers” refers to fibers whichhave been formed from at least two different polymers extruded fromseparate extruders but spun together to form one fiber. Bi-componentfibers are also sometimes referred to as conjugate fibers ormulticomponent fibers. The polymers are arranged in substantiallyconstantly positioned distinct zones across the cross-section of thebi-component fibers and extend continuously along the length of thebi-component fibers. The configuration of such a bi-component fiber maybe, for example, a sheath/core arrangement wherein one polymer issurrounded by another, or may be a side-by-side arrangement, a piearrangement, or an “islands-in-the-sea” arrangement. Some specificexamples of fibers which can be used in the first nonwoven layer includepolyethylene/polypropylene side-by-side bi-component fibers. Anotherexample, is a polypropylene/polyethylene bi-component fiber where thepolyethylene is configured as a sheath and the polypropylene isconfigured as a core within the sheath. Still another example, is apolypropylene/polypropylene bi-component fiber where two differentpropylene polymers are configured in a side-by-side configuration.Additionally, embodiments are contemplated where the constituent fibersof the first nonwoven layer are crimped.

As used herein, the term “bi-constituent fibers” refers to fibers whichhave been formed from at least two polymers extruded from the sameextruder as a blend. Bi-constituent fibers do not have the variouspolymer components arranged in relatively constantly positioned distinctzones across the cross-sectional area of the fiber and the variouspolymers are usually not continuous along the entire length of thefiber, instead usually forming fibrils which start and end at random.Bi-constituent fibers are sometimes also referred to asmulti-constituent fibers.

As used herein, the term “non-round fibers” describes fibers having anon-round cross-section, and includes “shaped fibers” and “capillarychannel fibers.” Such fibers can be solid or hollow, and they can betri-lobal, delta-shaped, and can be fibers having capillary channels ontheir outer surfaces. The capillary channels can be of variouscross-sectional shapes such as “U-shaped”, “H-shaped”, “C-shaped” and“V-shaped”. One practical capillary channel fiber is T-401, designatedas 4DG fiber available from Fiber Innovation Technologies, Johnson City,Tenn. T-401 fiber is a polyethylene terephthalate (PET polyester).

In some embodiments, the first nonwoven layer and/or second nonwovenlayer is a nonwoven web in which there are minimal fiber-to-fiber bonds.For example, the first nonwoven layer and/or second nonwoven layer canbe a nonwoven web having a pattern of discrete thermal point bonds, asis commonly known in the art for nonwoven webs. In general, however, itis desirable to minimize the number of bond points and maximize thespacing so as to allow for maximum fiber mobility and dislocation duringformation of tufts and/or caps. In general, using fibers havingrelatively high diameters, and/or relatively high extension to break,and/or relatively high fiber mobility, might result in better and moredistinctly formed tufts and/or caps. In another embodiment, the firstnonwoven layer and/or the second nonwoven layer can be through airbonded nonwoven material.

Although nonwoven webs of the present invention disclosed herein aredescribed as a two layer web made from two nonwoven layers, it is notnecessary that it be limited to two layers. For example, a three-layeror more laminate can be made from three nonwoven layer. Embodiments arecontemplated where there are three or more layers of nonwoven material.

The first nonwoven layer and the second nonwoven layer of the nonwovenwebs 200A, 200B, 200C, 700, 800, and 900, (shown in FIGS. 2A-2C and 7-9,respectively), can be held in a face-to-face laminated relationship byvirtue of the “locking” effect of the tufts that extend through thediscrepancies in first nonwoven layer or second nonwoven layer asdescribed herein. In some embodiments (including the nonwoven webs 100Aand 100B shown in FIGS. 1A and 1B) it may be desirable to use adhesivesor thermal bonding or other bonding means, depending on the end useapplication of the nonwoven web. Additionally, it may be desirable toapply adhesive to at least a portion of one of the first nonwoven layerand/or the second nonwoven layer. For example, in some embodimentsadhesive, chemical bonding, resin or powder bonding, or thermal bondingbetween layers can be selectively applied to certain regions or all ofthe nonwoven layers. In the case of adhesive application, for example,adhesive can be applied in a continuous manner, such as by slot coating,or in a discontinuous manner, such as by spraying, extruding, and thelike. Discontinuous application of adhesive can be in the form ofstripes, bands, droplets, and the like. Any suitable adhesive may beutilized.

In one embodiment, after tufts and/or caps are formed, the nonwovenmaterial (the constituents of the first nonwoven layer, and/or theconstituents of the second nonwoven layer, and/or the resultant nonwovenweb that is a combination of the first nonwoven layer and the secondnonwoven layer) may be attached as described in U.S. Pat. No. 7,682,686.For example, the first nonwoven layer and the second nonwoven layer maybe attached adjacent the cap base 471 (shown in FIG. 4). As anotherexample, the first nonwoven layer and the second nonwoven layer may beattached adjacent an apex of the cap. In yet another example, the firstnonwoven layer and the second nonwoven layer may be attached adjacentthe cap base 471 and adjacent the apex of the cap. Regarding the aboveembodiments, attachment may be provided for each cap present or providedto less than the totality of caps.

Any suitable process for aperturing the first nonwoven layer and/or thesecond nonwoven layer may be utilized. However, the aperturing processselected should not preclude the liquid communication relationshipbetween the first nonwoven layer and the second nonwoven layer. Somesuitable aperturing processes for the first nonwoven layer and/or thesecond nonwoven layer are described in U.S. Pat. Nos. 5,628,097;5,916,661; 5,658,639; 6,884,494; and 7,037,569. Additional suitableprocesses are described in U.S. Pat. Nos. 8,679,391; 8,241,543; and8,158,043. Additionally, in some embodiments, aperturing may be achievedvia a spunlacing process. For example, the first nonwoven layer and/orthe second nonwoven layer may transported to a hydroentanglingapparatus. A carrier transporting the first and/or second nonwovenlayer, may comprise large openings which allow fluid to passtherethrough. During the hydroentangling process, the constituent fibersof the first and/or second nonwoven layers may be moved via the waterjets of the hydroentangling and generally mimic the pattern of thecarrier. As such, the first and/or second nonwoven layer may compriseapertures which mimic the openings in the carrier.

The aperturing of the first and/or second nonwoven layers may be doneseparately or contemporaneously where the first nonwoven layer and thesecond nonwoven layer are configured as a laminate web. The area of eachof the individual apertures of the present invention may be about 0.8mm² to about 4.0 mm² or, in some embodiments, from about 1.5 mm² toabout 2.5 mm², specifically including any values within these ranges orany ranges created thereby. In some embodiments, the overall open areaof the first nonwoven layer and/or the second nonwoven layer may be fromabout 9 percent to about 30 percent, specifically including all valueswithin this range and any ranges created thereby. The percentage openarea is defined as a ratio of the sum of the area of apertures dividedby the total area of the layer (apertures plus land areas).

It is worth noting that care should be exercised in selecting both theaperture area and overall open area. For example, while larger aperturesmay facilitate fluid acquisition into lower layers of an absorbentarticle, larger apertures can create a problem from a rewet standpoint.Additionally, larger aperture sizes can weaken the nonwoven to such anextent as to introduce tearing issues during manufacture or during useby the wearer.

Hydrophobic Additive

As mentioned previously, the first nonwoven layers described herein,comprise a first plurality of substantially randomly oriented fibers.Additionally, the first nonwoven layers described herein may comprise anadditive which blooms on a surface of at least a portion of the firstplurality of fibers. The additive may be applied on the fibers postproduction or may be added directly or as master batch to the polymermelt during spinning of the filaments as a melt additive. For thoseembodiments where the additive is melt blended into the filaments, theadditive can bloom to the surface of the fibers and create a filmcovering a portion of the external surface of the fiber and/or cancreate fibrils, flakes, particles, and/or other surface features. Forthose embodiments where the additive is applied to the fibers postproduction, the additive can form particles, films, flakes, and/ordroplets. For those fibers comprising fibrils, the fibrils may extendoutwardly, or radially outwardly, from the surface.

While the fibrils extend outwardly from surfaces of individual fibers,the fibrils may also extend to or from (i.e., contact) other fiberswithin the same layer or a different layer of a nonwoven substrateand/or to fibrils extending from fibers within the same layer or adifferent layer of the nonwoven substrate. When the fibrils extendbetween fibers and/or other fibrils, the nonwoven substrate may achievea greater liquid contact angle for polar and non-polar liquids. Asimilar effect may be obtained for additives which are applied to thefirst plurality of fibers post production. Without wishing to be boundby theory, it is believed that the additive, regardless of whether amelt additive or applied post fiber production, changes the surfaceenergy of the constituent fibers. The change in surface energy increasesthe hydrophobic nature of the constituent fibers and therefore the firstnonwoven layer. Additionally, it is believed that the additive, whethera melt additive or applied post fiber production, increases the surfaceroughness of the constituent fibers which can increase hydrophobicity.It is believed that an increase in hydrophobicity due to surfaceroughness is achieved by metastable Wenzel and stable Cassie-Baxternon-wetting states.

The additive suitable for the present invention may be any suitablehydrophobic additive. Thus, the additives may increase thehydrophobicity of the fibers upon whose surface they bloom. This canlead to increased low surface tension fluid strikethrough times andhigher hydrophobicity for the first nonwoven layer and/or when comparedto the second nonwoven layer.

Some examples of suitable additives include fatty alcohols and fattyacid esters. Non-limiting examples of suitable fatty alcohols havingfrom about 12 to about 24 carbon atoms include saturated,un-substituted, monohydric alcohols or combinations thereof, which havea melting point less than about 110° C., preferably from about 45° C. toabout 110° C. Specific examples of fatty alcohol carriers for use in theskin care compositions of the present invention include, but are notlimited to, cetyl alcohol, stearyl alcohol, cetearyl alcohol, behenylalcohol, arachidyl alcohol, lignocaryl alcohol, and combinationsthereof. Examples of commercially available cetearyl alcohol are Stenol1822 and behenyl alcohol is Lanette 22, both of which are available fromthe Cognis Corporation located in Cincinnati, Ohio.

Non-limiting examples of suitable fatty acid esters include those fattyacid esters derived from a mixture of C₁₂-C₂₈ fatty acids and shortchain (C₁-C₈, preferably C₁-C₃) monohydric alcohols preferably from amixture of C₁₆-C₂₄ saturated fatty acids and short chain (C₁-C₈,preferably C₁-C₃) monohydric alcohols. Representative examples of suchesters include methyl palmitate, methyl stearate, isopropyl laurate,isopropyl myristate, isopropyl palmitate, ethylhexyl palmitate, andmixtures thereof. Suitable fatty acid esters can also be derived fromesters of longer chain fatty alcohols (C₁₂-C₂₈, preferably C₁₂-C₁₆) andshorter chain fatty acids such as lactic acid, specific examples ofwhich include lauryl lactate and cetyl lactate.

In some embodiments, the additives of the present disclosure, may have amelting point in the range of about 40 degrees C. to about 80 degreesC., about 55 degrees C. to about 75 degrees C., about 60 degrees C. toabout 73 degrees C., specifically reciting all one degree C. incrementswithin the specified ranges and all ranges formed therein or thereby. Invarious embodiments, the additives of the present disclosure may have amelting temperature above 30° C., above 40° C., or above 50° C., butless than 80 degrees C., including all ranges within the valuesexpressed and all numbers within the ranges created by the valuesexpressed.

In some embodiments, the additive may have a hydrophilic/lipophilicbalance (“HLB”) value of less than about 4. In some embodiments, the HLBvalue may be greater than about 0 and less than about 4, between about 1and about 3.5, between about 2 and about 3.3, or any ranges within thevalues provided or any value within the ranges provided. It is believedthat above an HLB value of about 4, the additive will start to take onmore surfactant-like hydrophilic properties and would thereby reduce thebenefit provided by the highly hydrophobic additive. Namely, asmentioned previously, the hydrophobic additive can provide a maskingbenefit which makes the disposable absorbent article utilizing thenonwoven web of the present invention appear more “clean” after a liquidinsult has occurred.

In some embodiments, the additive may have an IOB (inorganicvalue/organic value) value of greater than about 0 and less than about0.4, between about 0.1 and about 0.35, between about 0.2 and 0.33,specifically including all values within these ranges and any rangescreated thereby. The IOB value is discussed in additional detail in EPPatent Application Publication No. 2517689.

The additives used, may comprise fatty acid derivatives, such as a fattyacid ester; typically an ester formed from an alcohol with two or morehydroxyl groups and one or more fatty acids having between at least 12carbon atoms to 22 carbon atoms, or at least 14 carbon atoms, wherebywithin one ester compound, different fatty acid-derived groups may bepresent (herein referred to as fatty acid ester).

The fatty acid ester compound may be an ester of an alcohol carrying twoor more, or three or more, functional hydroxyl group per alcoholmolecule, whereby all of the hydroxyl groups form an ester bond withfatty acids (either the fatty acid or mixtures thereof).

In an embodiment, the alcohol may have three functional hydroxyl groups.It is understood that in a fatty acid ester having more than one esterbond, such as in di- or tri-glycerides, the fatty acid-derived group maybe the same, or they may be two or even three different fattyacids-derived groups. It is further understood that the additivecomponent may comprise a mixture of mono- di- and/or tri-fatty acidester (e.g. mono- di-, and/or triglyceride) esters with the samefatty-acid derived group per molecule, and/or with different fattyacid-derived groups without exceeding the scope of the invention.Preferred fatty acids in at least one embodiment may range from a C8fatty acid to a C30 fatty acid; or, in another embodiment range from aC12 fatty acid to a C22 fatty acid. Suitable vegetable fatty acidstypically include unsaturated fatty acids. The fatty acid may suitablybe selected from the group comprising an arachidec acid, a stearic acid,a palmitic acid, a myristic acid, a myristoleic acid, an oleic acid, alimoleic acid, a linolenic acid, and an arachidonic acid. In anotherfurther embodiment, a substantially saturated fatty acid is preferred,particularly when saturation arises as a result of hydrogenation offatty acid precursor. The fatty acids may range from a C12 fatty acid toa C22 fatty acid as illustrated in [1],

where R1, R2, and R3 each have a number of carbon atoms ranging from 11to 21. In at least one other embodiment, the fatty acids may range froma C16 fatty acid to a C20 fatty acid.

In at least one further embodiment, a substantially saturated fatty acidis preferred, particularly when saturation arises as a result ofhydrogenation of fatty acid precursor. In at least one furtherembodiment, a C18 fatty acid, stearic acid, is preferred. An example ofthe stearic acid-substituted fatty acid is[2-octadecanoyloxy-1-(octadecanoyloxymethyl)ethyl]octadecanoate having aCAS registry number of 555-43-1. It should be understood that thepreferred triglyceride ester has an esterified glycerol backbone havingno non-hydrogen sub-stitutents on the glycerol backbone.

In an embodiment, the one or more additives may comprise a mono- and/ordi-glyceride ester, and/or a triglyceride ester, (with one, two or threefatty acid-derived groups). It should be understood that while [1]illustrates a simple triglyceride in which all three pendent fatty acidsmay be the same, other embodiments may include a mixed triglyceride inwhich two or even three different pendent fatty acids are presentwithout exceeding the scope of the invention. It should be furtherunderstood that while the triglyceride ester is illustrated in [1] is asingle triglyceride ester formulation, the triglyceride ester used inthe preparation of the master batch may include a plurality oftriglyceride esters having different pendent fatty acid groups and/orone or more derivatives of the fatty acid, without exceeding the scopeof the invention. It should be further understood that while thetriglyceride ester illustrated in [1] is a monomer, the triglycerideester used in the preparation of the master batch may include apolymerized triglyceride ester, such as a polymerized, saturatedglyceride ester without exceeding the scope of the invention. It shouldbe further understood that the polymerized triglyceride ester maycomprise a mixture of polymers having different numbers of monomericunits included in the polymer. For example the polymerized triglycerideester may include a mixture of monoesters, diesters, and the like.

The fatty acids used to form the ester compounds include fatty acidderivatives for the purpose of the present disclosure. A mono-fatty acidester, or for example, amono-glyceride, comprises a single fatty acid,e.g., connected a glycerol; a di-fatty acid ester, or e.g.,di-glyceride, comprises two fatty acids, e.g., connected to theglycerol; a tri-fatty acid ester, or e.g. tri-glyceride, comprises threefatty acids, e.g., connected to a glycerol. In an embodiment, theadditive may comprise at least a triglyceride ester of fatty acids(i.e., the same or different fatty acids).

It should be understood that the triglyceride ester may have anesterified glycerol backbone having no nonhydrogen substituents on theglycerol backbone; however, the glycerol backbone may also compriseother substituents.

In an embodiment, the glycerol backbone of the glycerol ester may onlycomprise hydrogen. The glyceride esters may also comprise polymerized(e.g., tri) glyceride esters, such as a polymerized, saturated glycerideesters.

In a fatty acid ester having more than one ester bond, such as in di- ortri-glycerides, the fatty acid-derived group may be the same, or theymay be two or even three different fatty acids-derived groups.

The additive may comprise a mixture of mono-, di-, and/or tri-fatty acidester (e.g., mono- di- and/or triglyceride) esters with the samefatty-acid derived group per molecule, and/or with different fattyacid-derived groups.

The fatty acids may originate from vegetable, animal, and/or syntheticsources. Some fatty acids may range from a C8 fatty acid to a C30 fattyacid, or from a C12 fatty acid to a C22 fatty acid. Suitable vegetablefatty acids typically include unsaturated fatty acids such as oleicacid, palmitic acid, linoleic acid, and linolenic acid. The fatty acidmay be arachidec, stearic, palmitic, myristic, myristoleic, oleic,limoleic, linolenic, and/or arachidonic acid.

In another embodiment, a substantially saturated fatty acid may be used,particularly when saturation arises as a result of hydrogenation offatty acid precursor. In an embodiment, a C18 fatty acid, oroctadecanoic acid, or more commonly called stearic acid may be used toform an ester bond of the fatty acid ester herein; stearic acid may bederived from animal fat and oils as well as some vegetable oils. Thestearic acid may also be prepared by hydrogenation of vegetable oils,such as cottonseed oil. The fatty acid ester herein may comprise fattyacids of mixed hydrogenated vegetable oil, such as one having CASregistration number 68334-28-1.

At least one stearic acid, at least two, or three stearic acids areconnected to a glycerol, to form a glycerol tristearate, for theadditive herein. In an embodiment, the additive may comprise a glyceroltristearate (CAS No. 555-43-1), also known by such names as tristearinor 1,2,3-Trioctadecanoylglycerol. (In the following, the name glyceroltristearate will be used, and in case of doubt the CAS No., shall beseen as the primary identifier).

In other embodiments, additives with chemical structures similar toglycerol tristearate or tristearin such as triacylglycerols(triglycerides) including but not limited to trimyristin, tripalmitin,trilaurin, trimargarine, and waxes such as distearin, and mixtures ofsaturated and unsaturated glycerides, such as1,3-distearoyl-2-oleoylglycerol (SOS) may be utilized. Non-limitingexamples additives having molecular and crystallite structures assimilar to tristearin include Alkylketene dimers (AKD), inorganic andorganic salts of fatty acids (also known as alkyl carboxylic acids) thatcomprise of alkyl chains that are mostly saturated, and contain between12 and 22 carbon atoms. Non-limiting examples of salts of fatty acidsinclude zinc stearate, calcium stearate, magnesium stearate, titaniumstearate, silver stearate, aluminum di- and tri-stearates, aluminumtripalmitate, aluminum trimyristate, aluminum trilaurate, sorbitantristearate, sorbitan tripalmitate, sorbitan trimyristate, sorbitantrilaurate, and combinations thereof, which are believed to form flakyand fibrillar lamellar structures on surfaces due to blooming.

In an embodiment, the fatty acid ester of the additive may have anumber-averaged molecular weight ranging from 500 to 2000, from 650 to1200, or from 750 to 1000, specifically reciting all whole integerincrements within the above-specified ranges and any ranges formedtherein or thereby.

The additive may comprise very little or no halogen atoms; for example,the additive may comprise less than 5 wt. % halogen atoms (by weight ofthe additive), or less than 1 wt. %, or less than 0.1 wt. % of theadditive; the additive may be substantially halogen-free.

In an embodiment, the additive may be or may comprise a lipid ester orglycerol tristearate. In various embodiments, the fibrils may comprise,consist of, or consist essentially of (i.e., 51% to 100%, 51% to 99%,60% to 99%, 70% to 95%, 75% to 95%, 80% to 95%, specifically includingall 0.1% increments within the specified ranges and all ranges formedtherein or thereby) of the additive.

Nonlimiting examples of suitable alkyl ethoxylates include C₁₂-C₂₂ fattyalcohol ethoxylates having an average degree of ethoxylation of fromabout 2 to about 30. Non-limiting examples of suitable lower alcoholshaving from about 1 to about 6 carbon atoms include ethanol,isopropanol, butanediol, 1,2,4-butanetriol, 1,2 hexanediol, etherpropanol, and mixtures thereof. Non-limiting examples of suitable lowmolecular weight glycols and polyols include ethylene glycol,polyethylene glycol (e.g., Molecular Weight 200-600 g/mole), butyleneglycol, propylene glycol, polypropylene glycol (e.g., Molecular Weight425-2025 g/mole), and mixtures thereof.

The master batch added to the composition from which the fibers of thepresent disclosure are formed may be the master batch disclosed in U.S.Pat. No. 8,026,188 to Mor.

In an embodiment, the fibrils may grow out of the fibers post-nonwovensubstrate formation under ambient conditions. The fibrils may benoticeable using an SEM after about 6 hours post-nonwoven substrateformation under ambient conditions. Fibril growth may reach a plateauafter about 50 hours, 75 hours, 100 hours, 200 hours, or 300 hourspost-nonwoven substrate formation under ambient conditions. In someembodiments, fibril growth may continue well beyond 300 hours. The timerange of noticeable fibril growth post-nonwoven substrate formation maybe in the range of 1 minute to 300 hours, 5 hours to 250 hours, 6 hoursto 200 hours, 6 hours to 100 hours, 6 hours to 24 hours, 6 hours to 48hours, or 6 hours to 72 hours, under ambient conditions, specificallyreciting all 1 minute increments within the above specified ranges andall ranges formed therein or thereby. The time to allow full fibrilgrowth post-nonwoven substrate formation may be 12 hours, 24 hours, 48hours, 60 hours, 72 hours, 100 hours, or 200 hours, for example, underambient conditions. In some embodiments, fibril growth may occur almostimmediately post nonwoven production.

Typical size scale of fibril or flake or other surface structuresprotruding from surface due to blooming may be of the order of fewnanometers to few tens of micrometers. For example, the average lengthof the bloomed surface structures can range from about 5 nanometers toabout 50 micrometers, from about 100 nanometers to about 30 micrometers,or from about 500 nanometers to about 20 micrometers. Preferred averagewidth of the bloomed surface structures can range from about 5nanometers to about 50 micrometers, from about 100 nanometers to about20 micrometers, or from about 500 nanometers to about 5 micrometers.Preferred average thickness of the bloomed surface structures wouldrange from about 5 nanometers to about 10 micrometers, more preferablyfrom about 50 nanometers to about 5 micrometers, and most preferablyfrom about 100 nanometers to about 1 micrometers. Preferred averagehydraulic diameter, calculated as 4*(Cross-sectionalArea)/(Cross-sectional Perimeter) of the bloomed surface structure canrange from about 5 nanometers to about 20 micrometers, from about 50nanometers to about 10 micrometers, or from about 100 nanometers toabout 1.5 micrometers. In a specific embodiment, the average hydraulicdiameter of a fibril is in the range of from about 100 nanometers toabout 800 nanometers. Average separation of the bloomed surfacestructures from one another can range from about 100 nanometers to about20 micrometers, from about 500 nanometers to about 10 micrometers, orfrom about 500 nanometers to about 5 micrometers.

The nonwoven substrates of the present disclosure having at least onelayer comprising fibers comprising fibrils may be configured to besofter or harder than, or have the same softness as, conventionalnonwoven substrates and/or may have a rougher, smoother, or the sametactile property as compared to conventional nonwoven substrates. Thesoftness, hardness, and/or tactile property of the nonwoven substratesmay vary depending on the type and amount of lipid esters present in thecomposition used to form the fibers and the length of the fibrils, forexample. The softness, hardness, and/or texture may also vary dependingon where the one or more layers of fibers having fibrils are positionedwithin a nonwoven substrate.

In an embodiment, the fibrils/droplets may have a different color thanthe fibers from which they grow. Stated another way, the fibrils mayhave a first color and the fibers from which they grow may have a secondcolor in non-fibril areas of the fibers. The first color may bedifferent than the second color (e.g., the fibers in non-fibril areasmay be white and the fibrils may be blue or the fibers in non-fibrilareas may be light blue and the fibrils may be dark blue). This colorvariation can be accomplished by adding a colorant, such as a pigment ordye to the lipid esters before they are mixed into the composition usedto form the fibers. When the additive blooms from the fibers, they canbe a different color than the fibers from which they grow, therebyproducing a color contrast between the fibrils and the fibers from whichthey grow. In an embodiment, the first nonwoven layer comprising thefibers comprising the fibrils may appear to change color over a periodof time (i.e., the period of time in which the fibrils grow or a portionthereof) due to the contrasting color of the fibrils with respect to thefibers from which they grow. Different layers of fibers may havedifferent colored fibrils and/or fiber therein within the same nonwovensubstrate. In an embodiment, the colorant added to the lipid esters maybe dissolvable in urine, menses, runny BM, other bodily fluid, or otherfluid (e.g., water). In various embodiments, the dissolving colorant inthe fibrils may be used as a wetness indicator in an absorbent article,for example.

For those embodiments where the hydrophobic additive is applied postfiber production, the additive may be selectively applied. For example,the additive may be applied in a first area of the nonwoven web and maynot be applied in a second area. As another example, the additive may beapplied in specific patterns with void spaces to encourage fluiddrainage to the second nonwoven layer. The additive may be applied at abasis weight of from about 0.1 gsm to 10 gsm, preferably <1 gsm. Theadditive may be blended with other melt additive or topical ingredients,for example in a lotion composition. The additive may be applieduniformly throughout the nonwoven material or alternatively be appliedin zones or layers or gradients, for example preferentially in thecenter portion of a topsheet. For those embodiments where bi-componentfibers are utilized, the additive may be present at the same level ineach of the constituents of the bi-component fiber, may be at differentlevels with regard to the constituents of the bi-component fiber, or maybe preset in one constituent but not the other of a bi-component fiber.

For those embodiments where the hydrophobic additive is provided as amelt additive, e.g. part of the master batch, preferably between 0.5percent by weight to about 20 percent by weight, preferably less than 10percent by weight or any range within these values or any value withinthese ranges.

The additive may be applied to the fibers of the nonwoven web by anysuitable process. Some examples include spraying, slot coating, or thelike. Other suitable hydrophobic additives are available from TechmerPM, LLC.

Embodiments are contemplated where the first nonwoven layer and/or thesecond nonwoven layer include compositions in addition to the additive.Some examples include lotions, skin care actives, odor absorbing orinhibiting or masking, fragrances, pigments, dyes, agents affecting thecoefficient of friction, antimicrobial/antibacterial agents, the like orcombinations thereof.

EXAMPLES

FIG. 11 is an SEM photo of a polypropylene fiber with glyceroltristearate additive added to the fibers as a master batch (8 wt %Techmer PPM17000 High Load Hydrophobic). The masterbatch comprised about60 percent by weight polypropylene and about 40 percent by weightglycerol tristearate. As shown the fiber 1191 comprise a plurality offibrils 1192 extending from the surface thereof.

FIG. 12 is an SEM photo of a bi-component fiber 1291 of polyethylene andpolypropylene arranged in 30/70 sheath/core configuration—thepolyethylene being the sheath. The additive (glycerol tristearate) wasadded to the fibers as a master batch (17% of Techmer PPM 17000 HighLoad Hydrophobic). The master batch comprised about 60 percent by weightpolyethylene and about 40 percent by weight glycerol tristearate. Thesheath of the fiber comprised 17 percent by weight master batch and 83percent by weight polyethylene. As shown, the fiber 1291 comprises aplurality of fibrils 1292 extending therefrom.

FIG. 13 is an SEM photo of a bi-component fiber 1391 of polyethylene andpolypropylene arranged in 30/70 sheath/core configuration—polyethylenebeing the sheath. The additive (glycerol tristearate) was added to thefibers as a master batch. The master batch comprised about 60 percent byweight polyethylene and about 40 percent by weight glycerol tristearate.The sheath of the fiber comprised 30 percent by weight master batch and70 percent by weight polyethylene. As shown, the fiber 1391 comprises aplurality of fibrils 1392 extending therefrom.

FIGS. 14 and 15 demonstrate that the additive can be added variably withregard to differing components of a fiber. FIG. 14 is an SEM photo of apolypropylene/polyethylene bi-component fiber 1491 where thepolypropylene and the polyethylene are configured side byside—polyethylene 1491A and polypropylene 1491B. The additive was addedat varying levels as a master batch (Techmer PPM17000 High LoadHydrophobic)—10% master batch was added to the polypropylene componentand 5% of the same master batch was added to the polyethylene component.

FIG. 15 is an SEM photo of a polypropylene/polyethylene bi-componentfiber 1591 where the polypropylene and polyethylene are configured sideby side—polypropylene 1591A and polyethylene 1591B comprising fibrils1592. The additive was added at varying levels as a master batch(Techmer PPM17000 High Load Hydrophobic)—16% master batch was added tothe polypropylene component and 8% master batch was added to thepolyethylene component. In some instances, the additive may bloom moreon one side of the bi-component fiber 1591 than the other.

FIG. 16 is an SEM photo showing a plurality of fibers of a nonwovenwhere the additive has been applied post fiber production. As shown, theadditive forms a plurality of droplets/particles 1692 on the surface ofthe fibers.

FIGS. 17 and 18 are SEM photos showing fibers comprising a meltadditive. In FIG. 17, the additive has bloomed to the surface of thefibers to form a film, and in FIG. 18, the additive has bloomed to thesurface of the fiber to form a film/fibril combination. In FIG. 17,polypropylene fibers with 16 percent by weight master batch (TechmerPPM17000 High Load Hydrophobic) are shown.

In FIG. 18, the fibers are bi-component polypropylene/polyethylenefibers in a side by side configuration. The polypropylene comprises 16percent by weight master batch (Techmer PPM17000 High Load Hydrophobic),and the polyethylene component comprises 8 percent by weight of the samemaster batch.

In FIGS. 19A-19C nonwoven layers comprising fibers with hydrophobic meltadditive are shown; however, the melt additive did not present itself inthe form of fibrils. In FIG. 19A, the fibers are 2.6 denier per filamentand comprise 60/40 side/side polypropylene/polypropylene, using LyondellBasell HP561R in the first component and Lyondell Basell HP552 R in thesecond component. Both components additionally comprise 16% TechmerPPM17000 High Load Hydrophobic masterbatch, and 1% of TiO₂ masterbatch(MBWhite009). In FIG. 19A, the hydrophobic melt additive creates awrinkled texture on the fiber surface.

In FIGS. 19B and 19C, a nonwoven layer comprising fibers having a denierof 2.0 and comprise 60/40 side/side polypropylene/polypropylene, usingLyondell Basell HP561R in the first component and Lyondell Basell HP552R in the second component. Both components additionally comprise 10%Techmer PPM17000 High Load Hydrophobic masterbatch, and 1% of TiO₂masterbatch (MBWhite009). As shown, the lower amount of hydrophobic meltadditive does not provide the same surface structure as that depictedwith regard to FIG. 19A. But some wrinkled structures are seen in FIG.19B.

FIGS. 20A-20C show examples of nonwoven webs comprising a spray onhydrophobic additive. For example, as shown in FIG. 20A, fibers 2091 ofa nonwoven web were spray coated with glycerol tristearate 2092 at abasis weight of about 5 gsm. It is worth noting that the sprayapplication appears to leave large portions of the fibers 2091uncovered. Regarding FIG. 20B, the fibers 2091 were spray coated withglycerol tristearate 2092 at a basis weight of about 10 gsm. RegardingFIG. 20C, the fibers 2091 were spray coated with glycerol tristearate2092 at a basis weight of about 20 gsm.

Laminates Comprising Examples.

Four total laminates were made, two of the laminates comprised examplesabove. Rewet data was gathered for the laminates post a cumulativeliquid insult of about 21 ml of artificial menstrual fluid.

Laminate 1 was a 25 gsm spubond bi-component fiber nonwoven. Thefilaments were 2.5 denier per filament and comprised a 50/50 sheath coreconfiguration of polyethylene/polypropylene. The lower layer was asdescribed with regard to Laminate 2.

Laminate 2 comprised an upper layer which was described with regard toFIG. 12 and a lower layer comprising bi-component fibers spunbond withtopical hydrophilic surfactant. The basis weight of the lower layer was28 gsm, 2.8 denier per filament, 50/50 sheath/core,polyethylene/polypropylene. The web was coated with 0.4% by weightSilastol PHP26 surfactant made by Schill & Seilacher, Germany.

Laminate 3 is the same as Laminate 4 but without the melt additive inthe upper layer. Laminate 4 comprised an upper layer which was describedwith regard to FIGS. 19B and 19C and a lower layer comprising crimpedfiber spunbond with topical hydrophilic surfactant. The lower layercomprised fibers having 2.6 denier per filament, 70/30 side/side,polypropylene/polypropylene, using Lyondell Basell HP561R in the firstcomponent and Lyondell Basell HP552 R in the second component. Bothcomponents additionally comprise 1% of TiO₂ masterbatch (MBWhite009).The lower layer was coated with 0.4% by weight Silastol PHP26 surfactantmade by Schill & Seilacher, Germany.

Laminates 2 and 4 had lower rewet scores than laminates 1 and 3. BecauseLaminates 2 and 4 comprised an upper nonwoven layer which comprised ahydrophobic melt additive, it is believed that the hydrophobic meltadditive can provide laminates with a rewet benefit.

Tests HLB (Hydrophilic/Lipophilic Balance)

The term “HLB” or “HLB value” of a surfactant refers to theHydrophilic-Lipophilic Balance and is a measure of the degree to whichit is hydrophilic or lipophilic, determined by calculating values forthe different regions of the molecule. For nonionic surfactants theHLB=20*Mb/M, where M is the molecular mass of the whole molecule and Mbis the molecular mass of the hydrophilic portion of the Molecule. An HLBvalue of 0 corresponds to a completely lipidphilic/hydrophobic molecule,and a value of 20 corresponds to a completely hydrophilic/lipidphobicmolecule. The above represents the Griffin method of HLB calculationwhich is well known in the art.

Basis Weight Test

A 9.00 cm² large piece of nonwoven substrate, i.e., 1.0 cm wide by 9.0cm long, is used. The sample may be cut out of a consumer product, suchas a wipe or an absorbent article or a packaging material therefor. Thesample needs to be dry and free from other materials like glue or dust.Samples are conditioned at 23° Celsius (±2° C.) and at a relativehumidity of about 50% (±5%) for 2 hours to reach equilibrium. The weightof the cut nonwoven substrate is measured on a scale with accuracy to0.0001 g. The resulting mass is divided by the specimen area to give aresult in g/m² (gsm). Repeat the same procedure for at least 20specimens from 20 identical consumer products or packaging materialstherefor. If the consumer product or packaging materials therefor arelarge enough, more than one specimen can be obtained from each. Anexample of a sample is a portion of a topsheet of an absorbent article.If the local basis weight variation test is done, those same samples anddata are used for calculating and reporting the average basis weight.

Fiber Diameter and Denier Test

The diameter of fibers in a sample of a nonwoven substrate is determinedby using a Scanning Electron Microscope (SEM) and image analysissoftware. A magnification of 500 to 10,000 times is chosen such that thefibers are suitably enlarged for measurement. The samples are sputteredwith gold or a palladium compound to avoid electric charging andvibrations of the fibers in the electron beam. A manual procedure fordetermining the fiber diameters is used. Using a mouse and a cursortool, the edge of a randomly selected fiber is sought and then measuredacross its width (i.e., perpendicular to fiber direction at that point)to the other edge of the fiber. For non-circular fibers, the area of thecross-section is measured using the image analysis software. Theeffective diameter is then calculated by calculating the diameter as ifthe found area was that of a circle. A scaled and calibrated imageanalysis tool provides the scaling to get actual reading in micrometers(μm). Several fibers are thus randomly selected across the sample of thenonwoven substrate using the SEM. At least two specimens from thenonwoven substrate are cut and tested in this manner. Altogether, atleast 100 such measurements are made and then all data is recorded forstatistical analysis. The recorded data is used to calculate average(mean) of the fiber diameters, standard deviation of the fiberdiameters, and median of the fiber diameters. Another useful statisticis the calculation of the amount of the population of fibers that isbelow a certain upper limit. To determine this statistic, the softwareis programmed to count how many results of the fiber diameters are belowan upper limit and that count (divided by total number of data andmultiplied by 100%) is reported in percent as percent below the upperlimit, such as percent below 1 micrometer diameter or %-submicron, forexample.

If the results are to be reported in denier, then the followingcalculations are made.

Fiber Diameter in denier=Cross-sectional area (in m2)*density (inkg/m3)*9000 m*1000 g/kg.

For round fibers, the cross-sectional area is defined by the equation:

A=π*(D/2){circumflex over ( )}2.

The density for polypropylene, for example, may be taken as 910 kg/m3.

Given the fiber diameter in denier, the physical circular fiber diameterin meters (or micrometers) is calculated from these relationships andvice versa. We denote the measured diameter (in microns) of anindividual circular fiber as D.

In case the fibers have non-circular cross-sections, the measurement ofthe fiber diameter is determined as and set equal to the hydraulicdiameter, as discussed above.

Specific Surface Area

The specific surface area of the nonwoven substrates of the presentdisclosure is determined by Krypton gas adsorption using a MicromeriticASAP 2420 or equivalent instrument, using the continuous saturationvapor pressure (P_(o)) method (according to ASTM D-6556-10), andfollowing the principles and calculations of Brunauer, Emmett, andTeller, with a Kr-BET gas adsorption technique including automatic degasand thermal correction. Note that the specimens should not be degassedat 300 degrees Celsius as the method recommends, but instead should bedegassed at room temperature. The specific surface area should bereported in m²/g.

Obtaining Samples of Nonwoven Substrates

Each surface area measurement is taken from a specimen totaling 1 g ofthe nonwoven substrate of the present disclosure. In order to achieve 1g of material, multiple specimens may be taken from one or moreabsorbent articles, one or more packages, or one or more wipes,depending on whether absorbent articles, packages, or wipes are beingtested. Wet wipe specimens will be dried at 40 degrees C. for two hoursor until liquid does not leak out of the specimen under light pressure.The specimens are cut from the absorbent articles, packages, or wipes(depending on whether absorbent articles, packages, or wipes are beingtested) in areas free of, or substantially free of, adhesives usingscissors. An ultraviolet fluorescence analysis cabinet is then used onthe specimens to detect the presence of adhesives, as the adhesives willfluoresce under this light. Other methods of detecting the presence ofadhesives may also be used. Areas of the specimens showing the presenceof adhesives are cut away from the specimens, such that the specimensare free of the adhesives. The specimens may now be tested using thespecific surface areafibrils method above.

Fibril Length Measurement Test

1) Using a software program such as Image J software, measure the numberof pixels within the length of the legend on an SEM image of a nonwovensubstrate using a straight line (i.e., a line with a length and nothickness). Record the length of the line and the number of microns thatthe legend corresponds to.

2) Pick a fibril and measure its length from its free end to the endoriginating out of the fiber as best visualized. Record the length ofthe line.

3) Divide this length by the length of the legend in pixels and thenmultiply by the length of the legend in microns to get the length of thefibril in microns.

If the fibrils are long and curly, then the length of such fibrils istaken in linear increments.

Fibril Width Measurement Test

1) Using a software program such as Image J software, measure the numberof pixels within the length of the legend on an SEM image of a nonwovensubstrate using a straight line (i.e., a line with a length and nothickness). Record the length of the line and the number of microns thatthe legend corresponds to.

2) Pick a fibril and measure its width as best visualized. Record thelength of the line.

3) Divide this width by the length of the legend in pixels and thenmultiply by the length of the legend in microns to get the width of thefibril in microns.

If the fibrils are curved, then the width of such fibrils is taken inlinear increments.

Fibril Thickness Measurement Test

1) Using a software program such as Image J software, measure the numberof pixels within the length of the legend on an SEM image of a nonwovensubstrate using a straight line (i.e., a line with a length and nothickness). Record the length of the line and the number of microns thatthe legend corresponds to.

2) Pick a fibril and measure its thickness as best visualized. Recordthe length of the line.

3) Divide this thickness by the length of the legend in pixels and thenmultiply by the length of the legend in microns to get the thickness ofthe fibril in microns.

If the fibril has variable thickness across its width, then thethickness of such fibril is taken as numeric average of measurementsacross its width.

Fibril Separation Measurement Test

1) Using a software program such as Image J software, measure the numberof pixels within the length of the legend on an SEM image of a nonwovensubstrate using a straight line (i.e., a line with a length and nothickness). Record the length of the line and the number of microns thatthe legend corresponds to.

2) Pick a fibril and measure its distance from one of its nearestneighbor as best visualized. Record the length of the line.

3) Divide this thickness by the length of the legend in pixels and thenmultiply by the length of the legend in microns to get the thickness ofthe fibril in microns.

Repeat steps (2) and (3) above to measure distance of the fibril fromthe rest of its nearest neighbors. Take numeric average of the measureddistances to calculate average separation distance of the fibrils.

Mass-Average Diameter

The mass-average diameter of fibers is calculated as follows:

$\mspace{20mu}{{{mass}\mspace{14mu}{average}\mspace{14mu}{diameter}},{d_{mass} = {\frac{\sum\limits_{i = 1}^{n}\left( {m_{i} \cdot d_{i}} \right)}{\sum\limits_{i = 1}^{n}m_{i}} = {\frac{\sum\limits_{i = 1}^{n}\left( {\rho \cdot V_{i} \cdot d_{i}} \right)}{\sum\limits_{i = 1}^{n}\left( {\rho \cdot V_{i}} \right)} = {\frac{\sum\limits_{i = 1}^{n}\left( {\rho \cdot \frac{\pi{d_{i}^{2} \cdot {\partial x}}}{4} \cdot d_{i}} \right)}{\sum\limits_{i = 1}^{n}\left( {\rho \cdot \frac{\pi{d_{i}^{2} \cdot {\partial x}}}{4}} \right)} = \frac{\sum\limits_{i = 1}^{n}d_{i}^{3}}{\sum\limits_{i = 1}^{n}d_{i}^{2}}}}}}}$

where

fibers in the sample are assumed to be circular/cylindrical,

d_(i)=measured diameter of the i^(th) fiber in the sample,

∂x=infinitesimal longitudinal section of fiber where its diameter ismeasured, same for all the fibers in the sample,

m_(i)=mass of the i^(th) fiber in the sample,

n=number of fibers whose diameter is measured in the sample

ρ=density of fibers in the sample, same for all the fibers in the sample

V_(i)=volume of the i^(th) fiber in the sample.

The mass-average fiber diameter should be reported in μm.

Gravimetric Weight Loss Test

The Gravimetric Weight Loss Test is used to determine the amount oflipid ester (e.g., GTS) in a nonwoven substrate of the presentdisclosure. One or more samples of the nonwoven substrate are placed,with the narrowest sample dimension no greater than 1 mm, into acetoneat a ratio of 1 g nonwoven substrate sample per 100 g of acetone using arefluxing flask system. First, the sample is weighed before being placedinto the reflux flask, and then the mixture of the sample and theacetone is heated to 60° C. for 20 hours. The sample is then removed andair dried for 60 minutes and a final weight of the sample is determined.The equation for calculating the weight percent lipid ester in thesample is:

weight % lipid ester=([initial mass of the sample−final mass of thesample]/[initial mass of the sample])×100%.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A nonwoven web for use in an absorbent article,the nonwoven web comprising: a spunbond nonwoven layer comprising afirst plurality of fibers, a generally planar first surface and agenerally planar second surface opposed to the first surface, whereinthe spunbond nonwoven layer comprises a first plurality of substantiallyrandomly oriented fibers, wherein the first nonwoven layer comprises anadditive which is disposed, at least in part, on at least a portion ofthe first plurality of fibers; wherein the additive comprises a fattyacid ester derived from a C8 to C30 fatty acid; wherein the additiveforms a plurality of droplets on the surface of the fibers, and a secondcarded nonwoven layer comprising a second plurality of fibers, agenerally planar first surface and a generally planar second surfaceopposed to the first surface, wherein the second nonwoven layer isattached to the first nonwoven layer such that at least a portion of thesecond plurality of fibers are in liquid communication with the firstnonwoven layer, wherein the first nonwoven layer is hydrophobic and thesecond nonwoven layer is hydrophilic.
 2. The nonwoven web of claim 1,wherein the additive is applied to the first plurality of fibers viaspraying or slot coating.
 3. The nonwoven web of claim 1, wherein thefirst plurality of fibers comprises polypropylene or polyethylene andthe second plurality of fibers comprises rayon or cotton.
 4. Thenonwoven web of claim 1, wherein the first plurality of fibers comprisesmonocomponent fibers.
 5. The nonwoven web of claim 1, wherein the firstplurality of fibers comprises bicomponent fibers.
 6. The nonwoven web ofclaim 1, wherein the first nonwoven layer comprises a first plurality ofapertures, and wherein the second nonwoven layer comprises a secondplurality of apertures which are substantially aligned with the firstplurality of apertures of the first nonwoven layer.
 7. The nonwoven webof claim 1, wherein the additive comprises a hydrophobic material withHLB value between 0 and
 4. 8. The nonwoven web of claim 7, wherein theadditive has a melting point in the range of about 40 degrees C. toabout 80 degrees C.
 9. The nonwoven web of claim 8, wherein the additivecomprises glycerol tristearate.
 10. The nonwoven web of claim 1, whereinthe additive is present in the first nonwoven layer at from betweenabout 1 percent to about 15 percent by weight.
 11. The nonwoven web ofclaim 5, wherein the bi-component fibers comprise a first polypropyleneand a second polypropylene arranged in a side by side configuration andare crimped.
 12. The nonwoven web of claim 11, wherein the additive isapplied to the first nonwoven layer at from between about 0.1 gsm toabout 10 gsm.
 13. The nonwoven web of claim 11, wherein the additive isprovided at different levels in each component.
 14. The nonwoven web ofclaim 1, wherein the first nonwoven layer further comprises a pluralityof caps, wherein each of the plurality of caps is positioned above thefirst surface of the first nonwoven layer and each of the plurality ofcaps at least partially overlies an opening of the plurality ofdiscontinuities.
 15. The nonwoven web of claim 1, wherein the firstplurality of fibers comprises bi-component fibers comprisingpolyethylene and polypropylene arranged in a sheath/core configuration.16. A nonwoven web for use in an absorbent article, the nonwoven webcomprising: a carded nonwoven layer comprising a first plurality offibers, a generally planar first surface and a generally planar secondsurface opposed to the first surface, wherein the first nonwoven layercomprises an additive which is disposed, at least in part, on at least aportion of the first plurality of fibers; wherein the additive comprisesa fatty acid ester derived from a C8 to C30 fatty acid; wherein theadditive forms a plurality of droplets on the surface of the fibers, anda second carded nonwoven layer comprising a second plurality of fibers,a generally planar first surface and a generally planar second surfaceopposed to the first surface, wherein the second nonwoven layer isattached to the first nonwoven layer such that at least a portion of thesecond plurality of fibers are in liquid communication with the firstnonwoven layer, wherein the first nonwoven layer is hydrophobic and thesecond nonwoven layer is hydrophilic.